Charger power distribution unit assembly tooling and charger installation method, charger

Abstract

The present invention discloses a charger distribution unit assembly tool, a charger installation method, and a charger. The charger distribution unit assembly tool includes a support tool and a limit tool. At least a first assembly mark and a second assembly mark are placed on the support tool, and the support tool at least limits the first assembly mark to the installation position, and the limit tool at least limits the second assembly mark to the installation position. The relative positions of the support tool and the limit tool can be changed, so that all assembly marks can be detached from the assembly tool after the assembly is completed. Through the above-mentioned arrangement, the present invention can assemble the entire distribution unit separately outside the shell when the charger is assembled, and is no longer limited by the shell space, which is conducive to personnel operation. Moreover, the entire assembly tool is designed according to the product structure, has a high degree of fit, and is not a closed space, which is conducive to timely inspection of the installation structure, convenient for error correction and correction, and improves the accuracy rate, reduces the scrap rate, and improves product quality.

Description

Technical Field

[0001] The present invention relates to the technical field of vehicle-mounted power distribution unit assembly, and in particular to a charger power distribution unit assembly tool, a charger installation method, and a charger. Background Art

[0002] With the rapid development of society, new energy vehicles have been gradually popularized in the automobile consumer market, and the requirements for vehicles are getting higher and higher. The on-board charger is a component of new energy vehicles. Small size, light weight and powerful functions are the pursuit of technological progress. The power distribution unit PDU in the charger is an important component of the power unit of the electric vehicle. The main power units in the car distribute power through the PDU module.

[0003] The charger is generally designed as a small metal box, in which the PDU is assembled with many parts. The complexity of the parts and the shell space directly affect the complexity of the whole machine process and the stability of the product. Therefore, it is very important to reduce the difficulty of parts assembly, simplify the assembly process and improve the accuracy of parts assembly.

[0004] The current charger PDU assembly status, such as Figure 1 As shown, the charger is usually assembled in a layer-by-layer assembly design from bottom to top. The bottom two-in-one is assembled first in the shell, and then the adapter board assembly, PCBA board, relay assembly, first copper busbar parts, and second copper busbar parts of the PDU module are assembled layer by layer on this basis. Since the shell design space is small, the installation is compact, and the operability space is small, it is easy to assemble it in place. In particular, if multiple parallel copper busbar parts cannot be accurately positioned during installation, it is easy to assemble them out of position and even cause poor contact or fail to meet the safety distance. All these reasons increase the difficulty of installation, resulting in low installation efficiency and easy errors. Summary of the invention

[0005] In order to solve the defects of the prior art that the power distribution unit (PDU) of the charging unit is difficult to install and inefficient, the present invention proposes a charger power distribution unit assembly tool, a charger installation method, and a charger.

[0006] The technical solution adopted by the present invention is that the charger distribution unit assembly tooling includes a supporting tooling and a limiting tooling, on which at least a first assembly mark and a second assembly mark are placed, and the supporting tooling at least limits the first assembly mark to the installation position, and the limiting tooling at least limits the second assembly mark to the installation position, and the relative positions of the supporting tooling and the limiting tooling can be changed so that all assembly marks can be detached from the assembly tooling after the assembly is completed.

[0007] Preferably, at least one side of the supporting tooling is a mounting surface, and a plurality of positioning posts and / or positioning holes are provided on the mounting surface for positioning, and the first assembly mark includes at least one assembly mark that cooperates with the positioning posts and / or positioning holes.

[0008] Preferably, one of the limiting tooling and the supporting tooling is provided with a positioning column, and the other of the limiting tooling and the supporting tooling is provided with a positioning hole matched with the positioning column.

[0009] Preferably, the limiting tool comprises a first limiting member and a second limiting member, the first limiting member is detachably connected to the supporting tool, and the second limiting member is detachably connected to the first limiting member and / or the supporting tool.

[0010] Preferably, a plurality of limiting grooves and / or limiting columns are provided on the first limiting member and the second limiting member, and the second assembly mark includes at least one assembly mark matched with the first limiting member and at least one assembly mark matched with the second limiting member.

[0011] Preferably, one of the first limiting member and the second limiting member is provided with a positioning column, and the other of the first limiting member and the second limiting member is provided with a positioning hole plugged with the positioning column.

[0012] Preferably, the first limiting member is plugged and limited with the supporting tooling along the horizontal direction, and the second limiting component is plugged and limited with the first limiting component along the vertical direction.

[0013] Preferably, the first limiting member and / or the second limiting member are both provided with a plurality of avoidance grooves, and the supporting tooling is provided with at least one rib groove for conveniently taking and placing the first assembly target.

[0014] The present invention also provides a charger installation method, the steps of which include:

[0015] The two-in-one component is installed in the shell, and the charging unit is assembled outside the shell using the charger distribution unit assembly tooling, and then the assembled distribution unit is installed in the shell and connected to the two-in-one component.

[0016] Preferably, the assembly tool comprises a supporting tool, a first stopper and a second stopper, and the steps for assembling the power distribution unit are as follows:

[0017] Install the adapter board assembly at the assembly position on the supporting fixture, and then fix the PCB board and the adapter board assembly;

[0018] The first stopper is horizontally plugged into the supporting fixture, and the first copper bar is installed at the assembly position through the first stopper;

[0019] The second limiting member is vertically inserted into the first limiting member, and the relay assembly is assembled at the same time, and then the second copper busbar is installed at the assembly position and fixed.

[0020] The present invention also provides a charger, which is assembled using the charger power distribution unit assembly tool as described above.

[0021] Compared with the prior art, the present invention has the following beneficial effects:

[0022] 1. When assembling the charger, the entire power distribution unit can be assembled separately outside the shell, no longer restricted by the shell space, which is conducive to personnel operation. In addition, the entire assembly tooling is designed according to the product structure, with a high degree of fit. It is not a closed space, which is conducive to timely inspection of the installation structure, convenient for error correction, improved accuracy, reduced scrap rate, and improved product quality.

[0023] 2. Compared with the traditional assembly line of layer-by-layer installation, this solution can assemble different parts simultaneously. For example, the shell and the two-in-one can form a production line, while the assembly of the power distribution unit can form another production line. Finally, the two can form the final product, which further improves the efficiency.

[0024] 3. Multiple limit components are used to limit the copper busbar parts that are prone to errors and are more complicated during the installation of the distribution unit. This can ensure the accuracy of installation, reduce the contact between multiple copper busbar parts, reduce the occurrence of insufficient safety distance, and increase the safety performance of the product. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The present invention is described in detail below with reference to the embodiments and accompanying drawings, wherein:

[0026] Figure 1 is a schematic structural diagram of a second limiting member;

[0027] Figure 2 is a schematic diagram of the structure of the second limiting member at an upward viewing angle;

[0028] Figure 3 is a structural diagram of the first limiter;

[0029] Figure 4 It is a schematic diagram of the assembly tool after assembly;

[0030] Figure 5 yes Figure 4 Explosion diagram of

[0031] Figure 6 Schematic diagram of the internal components of the charger housing in this embodiment;

[0032] Figure 7 yes Figure 6 Explosion diagram of

[0033] Figure 8 It is a structural schematic diagram of the adapter plate assembly installed on the supporting tooling;

[0034] Fig. 9 This is a schematic diagram when installing the PCB board;

[0035] Fig.10 It is a schematic diagram of installing the first limiter and the first copper bar parts;

[0036] Fig.11 It is a schematic diagram of installing the relay assembly;

[0037] Fig.12 This is the schematic diagram after the second copper busbar parts are installed;

[0038] Fig.13 is a schematic diagram of removing the first limiting member and the second limiting member after completing the assembly;

[0039] Fig.14 is a schematic diagram of the structure of the assembled power distribution unit;

[0040] Fig.15 yes Fig.14 Schematic diagram of the expanded insulation panel of the power distribution unit.

[0041] 1. Support tooling; 2. Positioning column; 3. Positioning hole; 4. First limit piece; 5. Second limit piece; 6. Limiting groove; 7. Limiting column; 9. Avoidance groove; 10. Rib groove; 11. Adapter board assembly; 12. PCB board; 13. First copper busbar parts; 14. Relay assembly; 15. Second copper busbar parts; 16. Screws; 17. Insulating sheet; 18. Two-in-one assembly. DETAILED DESCRIPTION

[0042] A charger power distribution unit assembly tool is used on a vehicle charger of a new energy vehicle, and is Figure 6-7 As shown, the charger generally includes a housing, a two-in-one component 18 installed at the lower part of the housing, and a power distribution unit PDU placed on the two-in-one component 18. The entire charger is generally presented in a small metal box, which is easy to carry and install.

[0043] Among them, the power distribution unit PDU includes many parts and is more complicated to install, such as Fig.15As shown, it generally includes a conversion board assembly, a PCB board 12, a first copper busbar component 13, a second copper busbar component 15, and a relay assembly 14. If the above multiple components are directly installed layer by layer inside the casing, due to the small design space of the casing, the installation is relatively compact, and the operable space is also small, which is easy to be misassembled. In particular, if multiple parallel copper busbar components cannot be accurately positioned during installation, it is easy to assemble out of position and even cause poor contact or fail to meet the safety distance. Various reasons increase the difficulty of installation, resulting in low installation efficiency and easy errors.

[0044] Therefore, if Figure 1-5 As shown, the charger power distribution unit assembly tooling includes a support tooling 1 and a limit tooling, on which at least a first assembly mark and a second assembly mark are placed, and the support tooling 1 at least limits the first assembly mark to the installation position, and the limit tooling at least limits the second assembly mark to the installation position, and the relative positions of the support tooling 1 and the limit tooling can be changed, so that all assembly marks can be detached from the assembly tooling after the assembly is completed. Through the above arrangement, when the charger is assembled, the entire power distribution unit can be assembled separately outside the shell, no longer restricted by the shell space, which is conducive to personnel operation, and the entire assembly tooling is designed according to the product structure, with a high degree of fit, and it is not a closed space, which is conducive to timely inspection of the installation structure, convenient for error correction, improved accuracy, reduced scrap rate, and improved product quality.

[0045] Further, at least one side of the support fixture 1 is a mounting surface, and a plurality of positioning posts 2 and / or positioning holes 3 for positioning are provided on the mounting surface, and the first assembly mark includes at least one assembly mark that cooperates with the positioning posts 2 and / or positioning holes 3. One of the limiting fixture and the support fixture 1 is provided with a positioning post 2, and the other of the limiting fixture and the support fixture 1 is provided with a positioning hole 3 that cooperates with the positioning post 2.

[0046] The limiting fixture includes a first limiting member 4 and a second limiting member 5, wherein the first limiting member 4 is detachably connected to the supporting fixture 1, and the second limiting member 5 is detachably connected to the first limiting member 4 and / or the supporting fixture 1. A plurality of limiting grooves 6 and / or limiting columns 7 are provided on the first limiting member 4 and the second limiting member 5, and the second assembly target includes at least one assembly target object that cooperates with the first limiting member 4 and at least one assembly target object that cooperates with the second limiting member 5.

[0047] One of the first limiting member 4 and the second limiting member 5 is provided with a positioning column 2, and the other of the first limiting member 4 and the second limiting member 5 is provided with a positioning hole 3 plugged with the positioning column 2. Moreover, the first limiting member 4 and the supporting fixture 1 are plugged and limited in the horizontal direction, and the second limiting component is plugged and limited in the vertical direction with the first limiting component. In order to facilitate installation, a plurality of avoidance grooves 9 are provided on the first limiting member 4 and / or the second limiting member 5, and at least one rib groove 10 is provided on the supporting fixture 1 for convenient placement of the first assembly target.

[0048] Examples, such as Figure 1-5 As shown, in this embodiment, the support tool 1 is in the shape of a rectangular box as a whole, and its upper end surface is the installation surface, and positioning columns 2 are respectively provided at the four corners and necessary positions. The positioning columns 2 can be protrusions or studs, and of course positioning pins can also be used. At the same time, an inclined rib groove 10 is opened on each side of the support tool 1, and the rib groove 10 is opened from the side of the support tool 1 to the installation surface, so as to facilitate the placement and removal of the assembly target. A pair of block structures are also provided at one end of the support tool 1, and a horizontal positioning hole 3 is horizontally opened on the block structure for installation with the first limit member 4.

[0049] During installation, if Figure 8-12 As shown, the adapter board assembly 11 is first placed on the installation surface, and the installation positioning effect is achieved through multiple positioning columns 2, and then the PCB board 12 is fixed to the adapter board assembly 11 with screws 16, and then the first limit member 4 is used to position and install the first copper busbar component 13.

[0050] like Figure 1-5 As shown, the first limit member 4 is placed at the end of the supporting tooling 1, and a protruding positioning column 2 is respectively provided at both ends thereof. When the first limit member 4 is pushed horizontally, it can be inserted into the positioning hole 3 opened on the two block structures of the supporting tooling 1, thereby completing the installation and positioning of the first limit member 4. It will not move to the sides, but can be withdrawn horizontally.

[0051] like Figure 1-5 As shown, the first limiting member 4 is in a step-shaped overall shape and includes a plug-in portion and a limiting portion. The step fits with the first copper busbar component 13, and the plug-in portion is provided with two avoidance grooves 9, which can be plugged in with the protrusions on the adapter plate assembly 11, and the limiting portion is provided with six concave limiting grooves 6, each of which corresponds to a fixed end of the first copper busbar component 13.

[0052] like Figure 8-12As shown, after the first copper bar component 13 is initially positioned, the relay assembly 14 is placed on the adapter board assembly 11, and the relay assembly 14 is fixed by screws, and then the second stopper 5 is installed, and under the joint action of the first stopper 4 and the second stopper 5, the first copper bar component 13, the second copper bar component 15 and the relay assembly 14 are fixed by bolts. Among them, one end of the second copper bar component 15 is connected to the relay assembly 14 and the first copper bar component, and the other end crosses the entire relay assembly 14 and is fixed on the other side.

[0053] like Figure 1-5 As shown, the second limiting member 5 is in the shape of a long strip as a whole, and six positioning columns 2 extending downward are integrally arranged on its bottom surface, and three avoidance grooves 9 are opened on the side. At the same time, six positioning holes 3 are correspondingly opened on the first limiting member 4, and the positioning holes 3 are all opened in the limiting grooves 6. When the second limiting member 5 is placed on the first limiting member 4, the positioning columns 2 and the positioning holes 3 can be used to cooperate to achieve plug-in installation and limiting.

[0054] It should be noted that a through hole is opened on each fixed end of the first copper busbar component 13. When the fixed end is placed in the limiting groove 6, the through hole is opposite to the positioning hole 3. Therefore, when the positioning column 2 of the second limiting component 5 is vertically inserted into the positioning hole 3, the positioning column 2 can also play a further limiting role on the first copper busbar component 13. Therefore, the positioning column 2 is the limiting column 7.

[0055] like Figure 8-12 As shown, after multiple limiting and fixing by the support fixture 1, the first limiting member 4 and the second limiting member 5, although the distribution unit has many parts, they can all be installed and positioned in an orderly and reasonable manner, and the stability is high, which is convenient for assembly. After the final assembly is completed, the second limiting component is removed upwards, and then the first limiting member 4 is removed horizontally. The operator can remove the assembled distribution unit as a whole from the support fixture 1 through the rib grooves 10 on both sides, and since there is no restriction of the casing at this time, the insulating sheets 17 on both sides of the distribution unit can be opened from the vertical state to the horizontal state. At this time, the operator can carefully observe whether the internal structure is assembled in place to ensure the qualified rate of the finished product.

[0056] In summary, if Figure 8-12 As shown, the installation method of the charger in this embodiment is as follows:

[0057] The two-in-one component is installed in the shell, and the charging unit is assembled outside the shell using the charger distribution unit assembly tool as described above, and then the assembled distribution unit is installed in the shell and connected to the two-in-one component.

[0058] Specifically, Figure 8-12 As shown, the steps for assembling the power distribution unit are as follows:

[0059] The adapter plate assembly 11 is installed in the assembly position on the support tooling 1, and then the PCB board 12 and the adapter plate assembly 11 are fixedly installed;

[0060] The first stopper 4 is horizontally plugged into the supporting fixture 1, and the first copper bar parts 13 are then installed at the assembly position through the first stopper 4;

[0061] The second stopper 5 is vertically plugged into the first stopper 4, and the relay assembly 14 is assembled at the same time. Then, the second copper busbar 15 is installed at the assembly position and fixed.

[0062] After completing the above installation, if Fig.13 As shown, the second limiter is taken out vertically upwards and the first limiter is taken out horizontally to the right, and the assembled power distribution unit can be obtained. Figure 14-15 As shown, if you want to check, you can unfold the insulating sheet that was originally folded upward to a horizontal position. At this time, you can check the internal assembly structure to ensure accurate installation and quality.

[0063] At the same time, this embodiment also proposes a charger, which is assembled using the charger power distribution unit assembly tool as described above.

[0064] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. The charger power distribution unit assembly tooling includes a support tooling and a limit tooling, which is characterized by: At least a first assembly mark and a second assembly mark are placed on the support tooling, and the support tooling at least limits the first assembly mark to the installation position, and the limiting tooling at least limits the second assembly mark to the installation position, and the relative positions of the support tooling and the limiting tooling can be changed, so that all assembly marks can be separated from the assembly tooling after the assembly is completed; The limiting fixture comprises a first limiting member and a second limiting member, the first limiting member is detachably connected to the supporting fixture, and the second limiting member is detachably connected to the first limiting member and / or the supporting fixture; The second assembly target includes at least one assembly target object matched with the first limiting member and at least one assembly target object matched with the second limiting member.

2. The charger power distribution unit assembly tool according to claim 1, characterized in that: At least one side of the supporting tool is a mounting surface, and a plurality of positioning posts and / or positioning holes are provided on the mounting surface for positioning, and the first assembly mark includes at least one assembly mark object cooperating with the positioning posts and / or positioning holes.

3. The charger power distribution unit assembly tool according to claim 1, characterized in that: One of the position limiting tool and the supporting tool is provided with a positioning column, and the other of the position limiting tool and the supporting tool is provided with a positioning hole matched with the positioning column.

4. The charger power distribution unit assembly tool according to claim 1, characterized in that: The first limiting member and the second limiting member are provided with a plurality of limiting grooves and / or limiting columns; the first limiting member and / or the second limiting member are both provided with a plurality of avoidance grooves, and the supporting tooling is provided with at least one rib groove for conveniently taking and placing the first assembly target.

5. The charger power distribution unit assembly tool according to claim 1, characterized in that: One of the first limiting member and the second limiting member is provided with a positioning column, and the other of the first limiting member and the second limiting member is provided with a positioning hole plugged with the positioning column.

6. The charger power distribution unit assembly tool according to claim 5, characterized in that: The first limiting member is plugged and limited with the supporting tooling along the horizontal direction, and the second limiting member is plugged and limited with the first limiting member along the vertical direction.

7. A charger installation method, characterized by the following steps: include: The two-in-one component is installed in the shell, and the charging unit is assembled outside the shell using the charger distribution unit assembly tool as described in any one of claims 1 to 6, and then the assembled distribution unit is installed in the shell and connected to the two-in-one component.

8. The installation method according to claim 7, characterized in that: The assembly tool comprises a supporting tool, a first stopper and a second stopper, and the steps for assembling the power distribution unit are as follows: Install the adapter plate assembly at the assembly position on the supporting fixture, and then fix the PCB board and the adapter plate assembly; The first stopper is horizontally plugged into the supporting fixture, and the first copper bar is installed at the assembly position through the first stopper; The second limiting member is vertically inserted into the first limiting member, and the relay assembly is assembled at the same time, and then the second copper busbar is installed at the assembly position and fixed.

9. A charger, characterized in that The charger power distribution unit is assembled using the charger power distribution unit assembly tool as described in any one of claims 1 to 6.

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