A control assembly for a new energy vehicle

Abstract

The present invention relates to the field of controllers for automobiles, specifically a control assembly for new energy vehicles, which includes a box body. A heat dissipation water channel is arranged inside the box body, and the heat dissipation water channel divides the internal space of the box body into an upper cavity and a lower cavity. Two HPD drive modules, two DCAC drive modules, a main contactor, three high-voltage distribution contactors, a high-voltage distribution fuse, a control board, a DC bus bar, a composite bus bar, and an AC bus bar are respectively arranged in the upper cavity. A drive board is arranged on each HPD drive module, and a board-mounted current sensor is arranged on the drive board. A magnetic ring and a Y-capacitor board are respectively arranged on the DC bus bar. Two capacitors are arranged in the lower cavity. The internal structure layout of the present invention is compact and reasonable, with a small volume, diverse functions, flexible cutting and matching, good electromagnetic compatibility, and is easy to be arranged, installed, maintained and used in a whole vehicle.

Description

Technical Field

[0001] The present invention relates to the field of vehicle controllers, and particularly to a control assembly for new energy vehicles. Background Art

[0002] With the continuous fermentation of the industrial revolution, a large number of advanced technologies have been applied to the field of new energy vehicles, promoting the rapid development of new energy vehicles. One of the cores of the new energy vehicle industry is the electric drive system. As a key component of the electric drive system of new energy vehicles, the motor controller covers disciplines such as electromechanics, electronics, heat transfer, fluid mechanics, electromagnetics, and simulation, and has received great attention from the automotive fields, universities, and research institutions at home and abroad.

[0003] At present, one type of motor controller developed is a product suitable for passenger vehicles with only single-motor control function, which is small in size and light in weight. However, if it is used in large commercial vehicles, additional components such as high-voltage distribution boxes, DCDC, and DCAC need to be configured, resulting in a large overall volume, high cost, and complex layout. Another type is a control assembly for commercial vehicles, which integrates functions such as multi-motor control, DCDC, high-voltage power distribution, and vehicle control in the same housing. However, at present, due to the low degree of modularization of the internal structure, the internal structure layout and the external interface layout are unreasonable, making its volume relatively large and weight relatively heavy, bringing certain difficulties to the vehicle layout and maintenance. Summary of the Invention

[0004] The technical problem to be solved by the present invention is that the existing control assembly has a large volume and unreasonable internal layout. To solve this problem, the present invention provides a control assembly for new energy vehicles, with a compact and reasonable internal structure layout and a small volume.

[0005] The content of the present invention is a control assembly for new energy vehicles, including a box body. A heat dissipation water channel is arranged inside the box body, and the heat dissipation water channel divides the internal space of the box body into an upper cavity and a lower cavity. Inside the upper cavity, two HPD drive modules, two DCAC drive modules, a main contactor, three high-voltage power distribution contactors, a high-voltage power distribution fuse, a control board, a DC bus bar, a composite bus bar, and an AC bus bar are respectively arranged. A drive board is arranged on each HPD drive module, and a board-mounted current sensor is arranged on the drive board. A magnetic ring and a Y capacitor board are respectively arranged on the DC bus bar. Two capacitors are arranged inside the lower cavity. The positive pole of the DC bus bar is connected to one end of the main contactor, and the negative pole of the DC bus bar is connected to the composite bus bar. The composite bus bar is respectively connected to the other end of the main contactor, two DCAC drive modules, two HPD drive modules, and two capacitors. The AC bus bar is connected to the HPD drive module. The high-voltage power distribution contactor is respectively connected to the positive and negative poles of the high-voltage power distribution fuse and the DC bus bar through the composite bus bar. The control board is connected to the HPD drive module and the DCAC drive module through wire harnesses respectively. The metal pins of the capacitors are respectively connected to the HPD drive module and the composite bus bar.

[0006] Further, a quick-insert high-voltage DC input interface and a dual-channel quick-insert AC output interface are respectively arranged on the lower side of the front part of the box body. The quick-insert high-voltage DC input interface is connected to the positive and negative poles of the DC busbar, and the dual-channel quick-insert AC output interface is connected to the AC busbar.

[0007] Further, a coolant inlet and outlet water pipe, a dual-channel DCAC output interface, and a three-channel high-voltage power distribution external interface are respectively arranged on the side part of one side of the box body. The coolant inlet and outlet water pipe is communicated with the heat dissipation water channel. The DCAC drive module is connected to the DCAC output interface through a wire harness, and the high-voltage power distribution contactor is connected to the high-voltage power distribution external interface through a wire harness.

[0008] Further, a micro switch is arranged inside the box body. The micro switch is respectively connected to the DCAC output interface, the high-voltage power distribution external interface, and the control board through wire harnesses.

[0009] Further, a DCDC module is arranged inside the box body. The DCDC module is located in the lower cavity. The DCDC module is respectively connected to the positive and negative poles of the DC busbar and the high-voltage power distribution fuse through wire harnesses.

[0010] Further, a DCDC output interface is arranged on the side part of the box body. The DCDC module is connected to the DCDC output interface through a composite busbar.

[0011] Further, a waterproof breathable valve and a low-voltage control interface are respectively arranged on the side part of the other side of the box body. The low-voltage control interface is connected to the control board through a wire harness.

[0012] Further, a pre-charge contactor and a distribution board are respectively arranged inside the box body. The distribution board is respectively connected to the high-voltage power distribution contactor, the main contactor, the pre-charge contactor, and the control board through wire harnesses.

[0013] Further, an upper cover plate is arranged on the upper part of the box body, and a lower cover plate is arranged on the lower part of the box body.

[0014] Further, a support plate is arranged inside the upper cavity. The high-voltage power distribution fuse is installed on the side part of the support plate, and the control board is installed on the upper part of the support plate.

[0015] The beneficial effects of the present invention are that the internal structure layout of the present invention is compact and reasonable, with a small volume, diverse functions and flexible cutting and matching, good electromagnetic compatibility, and easy to be arranged, installed, maintained and used in a whole vehicle. Description of the Drawings

[0016] Att Figure 1 is a schematic structural diagram of the present invention;

[0017] Att Figure 2 is another schematic structural diagram of the present invention;

[0018] Attached Figure 3 is an exploded view of the internal structure of the present invention;

[0019] Attached Figure 4 is a top view of the present invention, with the upper cover plate omitted in the figure;

[0020] Attached Figure 5 is a top view of the present invention, with the upper cover plate, high-voltage power distribution fuse, control board, power distribution board and support board omitted in the figure;

[0021] Attached Figure 6 is a bottom view of the present invention, with the lower cover plate omitted in the figure;

[0022] Attached Figure 7 is a vertical sectional schematic diagram of the present invention.

[0023] In the figure, 1: box body; 2: upper cover plate; 3: lower cover plate; 4a: first wiring base plate; 4b: second wiring base plate; 5: wiring cover plate; 6: coolant inlet and outlet water pipe; 7: DCAC output interface; 8: high-voltage power distribution external interface; 9: DCDC output interface; 10: DC input interface; 11: AC output interface; 12: cable clamp; 13: low-voltage control interface; 14: HPD drive module; 15: drive board; 16: on-board current sensor; 17: DCAC drive module; 18: main contactor; 19: pre-charge contactor; 20: high-voltage power distribution contactor; 21: high-voltage power distribution fuse; 22: control board; 23: power distribution board; 24: metal support board; 25: capacitor; 26: DCDC module; 27: DC bus bar; 28: composite bus bar; 29: AC bus bar; 30: independent current sensor; 31: magnetic ring; 32: Y capacitor board; 33: micro switch. Specific embodiments

[0024] As attached Figure 1-7As shown in the figure, a control assembly for a new energy vehicle includes a box body 1. A heat dissipation water channel is arranged inside the box body 1, and the heat dissipation water channel divides the internal space of the box body 1 into an upper cavity and a lower cavity. Inside the upper cavity, two HPD drive modules 14, two DCAC drive modules 17, a main contactor 18, three high-voltage distribution contactors 20, a high-voltage distribution fuse 21, a control board 22, a DC busbar 27, a composite busbar 28, and an AC busbar 29 are respectively arranged. The two DCAC drive modules 17, the main contactor 18, the three high-voltage distribution contactors 20, and the high-voltage distribution fuse 21 can all be freely and flexibly trimmed according to functional requirements; a drive board 15 is arranged on each HPD drive module 14, and a board-mounted current sensor 16 is arranged on the drive board 15. By trimming and combining these two HPD drive modules 14, the present invention can be changed into a plug-in, pure electric, or dual-module parallel drive mode; a magnetic ring 31 and a Y capacitor board 32 for electromagnetic compatibility functions are respectively arranged on the DC busbar 27. Two capacitors 25 are arranged inside the lower cavity. The two capacitors 25 respectively correspond to the two HPD drive modules 14 and can be trimmed and combined synchronously. The positive pole of the DC busbar 27 is connected to one end of the main contactor 18. An independent current sensor 30 is arranged at the positive pole of the DC busbar 27. The negative pole of the DC busbar 27 is connected to the composite busbar 28. The composite busbar 28 is respectively connected to the other end of the main contactor 18, the two DCAC drive modules 17, the two HPD drive modules 14, and the two capacitors 25. The AC busbar 29 is connected to the HPD drive module 14. The high-voltage distribution contactor 20 is respectively connected to the positive and negative poles of the high-voltage distribution fuse 21 and the DC busbar 27 through the composite busbar 28. The control board 22 is connected to the HPD drive module 14 and the DCAC drive module 17 through wire harnesses respectively. The metal pins of the capacitor 25 are respectively connected to the HPD drive module 14 and the composite busbar 28. The box body 1 is made of aluminum alloy material and is formed by die-casting under high pressure or die stamping, having the advantages of light weight and low production cost in large quantities; the interior of the box body 1 is arranged in two layers up and down and is separated by the middle heat dissipation water channel. The internal structure layout of the present invention is compact and reasonable, with a small volume, diverse functions, flexible trimming and matching, good electromagnetic compatibility, and is easy for vehicle layout, installation, maintenance, and use.

[0025] On the lower side of the front part of the described box body 1, a quick-insert high-voltage DC input interface 10 and a dual-channel quick-insert AC output interface 11 are respectively arranged. The quick-insert high-voltage DC input interface 10 is connected to the positive and negative poles of the DC busbar 27, and the dual-channel quick-insert AC output interface 11 is connected to the AC busbar 29. A first wiring base plate 4a or a second wiring base plate 4b is arranged on the box body 1. When the first wiring base plate 4a is arranged on the box body 1, the quick-insert high-voltage DC input interface 10 is connected to the box body 1 through the first wiring base plate 4a; when the second wiring base plate 4b is arranged on the box body 1, a cable clamp 12 that can conduct a larger current is arranged on the second wiring base plate 4b. The above-mentioned dual-module parallel AC output and DC input scheme has the advantages of high part utilization rate and strong compatibility, and can effectively reduce the development cost of the present invention.

[0026] On the side part of one side of the described box body 1, a coolant inlet and outlet water pipe 6, a dual-channel DCAC output interface 7, and a three-channel high-voltage power distribution external interface 8 are respectively arranged. The coolant inlet and outlet water pipe 6 is communicated with the heat dissipation water channel. The DCAC drive module 17 is connected to the DCAC output interface 7 through a wire harness, and the high-voltage power distribution contactor 20 is connected to the high-voltage power distribution external interface 8 through a wire harness. The dual-channel DCAC output interface 7 and the three-channel high-voltage power distribution external interface 8 can be flexibly cut and matched according to different functional requirements, and have the advantage of meeting various functional requirements by developing only one control assembly product.

[0027] A micro switch 33 for detecting the opening of the cover and the contact condition of the high-voltage plug and socket is arranged in the box body 1. The micro switch 33 is respectively connected to the DCAC output interface 7, the high-voltage power distribution external interface 8, and the control board 22 through wire harnesses.

[0028] A DCDC module 26 is arranged in the box body 1. The DCDC module 26 is located in the lower cavity. The DCDC module 26 is respectively connected to the positive and negative poles of the DC busbar 27 and the high-voltage power distribution fuse 21 through wire harnesses.

[0029] A DCDC output interface 9 is arranged on the side part of the box body 1. The DCDC module 26 is connected to the DCDC output interface 9 through a composite busbar 28.

[0030] A waterproof breathable valve and a low-voltage control interface 13 are respectively arranged on the side part of the other side of the box body 1. The low-voltage control interface 13 is connected to the control board 22 through a wire harness. The other side of the box body 1 can be the opposite side or the vertical side of the side part where the DCAC output interface 7 is arranged. The external electrical interfaces of the present invention are arranged in a clear hierarchy, with high and low voltages separated, and can be flexibly cut, matched, and transformed. All external interfaces are centrally arranged on the front and side that are easy to observe and operate, which is beneficial to the effective use of the vehicle space and the layout of the vehicle wire harness, and is convenient for personnel operation and maintenance.

[0031] A pre-charging contactor 19 and a power distribution board 23 are respectively arranged in the described box body 1, and the power distribution board 23 is connected to a high-voltage power distribution contactor 20, a main contactor 18, the pre-charging contactor 19, and a control board 22 through wiring harnesses respectively.

[0032] An upper cover plate 2 is arranged on the upper part of the described box body 1, and a lower cover plate 3 is arranged on the lower part of the box body 1.

[0033] A support plate 24 is arranged in the upper cavity. A high-voltage power distribution fuse 21 is installed on the side part of the support plate 24, and both the control board 22 and the power distribution board 23 are installed on the upper part of the support plate 24. Each component above and below the upper part of the support plate 24 can be electromagnetically shielded through the support plate 24. The support plate 24 is a metal support plate 24.

[0034] As Figure 7 shown, a partition is arranged in the middle of the box body 1, a hole is opened on the partition, the upper cavity is located above the partition, and the lower cavity is located below the partition. The HPD drive module 14 and the DCAC drive module 17 are installed on the upper part of the partition, and the capacitor 25 and the DCDC module 26 are installed on the lower part of the partition. The metal pins of the capacitor 25 arranged in the lower cavity pass through the hole on the partition and are connected to the HPD drive module 14 and the composite busbar 28 arranged in the upper cavity. The DCDC module 26 arranged in the lower cavity passes through the hole on the partition through a wiring harness and is connected to the fuse 21 in the upper cavity.

[0035] Each of the above components without specified fixing methods can be fixed on the box body 1 through fixing parts such as screws.

[0036] The present invention has functions of dual main drive motor control, dual auxiliary motor control, high-voltage power distribution, DCDC, and adhesion detection; all external interfaces are arranged on the front and side two surfaces; the high-voltage interfaces and low-voltage interfaces are separately and isolatedly arranged; the coolant inlet and outlet of the coolant inlet and outlet pipe 6 are arranged on the same side part of the box body 1; the present invention can be flexibly changed into a plug-in type, a pure electric type, or a dual-module parallel drive mode; the internal components of the present invention adopt a double-layer arrangement; the multi-way high-voltage power distribution function of the present invention can be flexibly cut and matched; the two-way DCAC function of the present invention can be flexibly cut and matched; each phase of direct current and alternating current of the present invention is equipped with a current sensor; the on-board current sensor is used for each phase of alternating current of the present invention; the radiator and the box body of the present invention are made of aluminum alloy materials and are formed by die-casting under high pressure or die stamping, having the advantages of light weight and low production cost in large quantities; magnetic rings and Y-capacitor plates with electromagnetic compatibility functions are installed on the direct current busbar of the present invention. The internal structure and external interface layout of the present invention are compact and reasonable, and the internal structure layout is reasonable, the external connection operation is convenient, the functions are diverse, it can be flexibly cut, the structure compatibility is strong, the present invention can solve the problems of complex structure of the commercial vehicle control assembly, difficult installation, arrangement and maintenance, high production cost, etc., meet the requirements of high reliability and low cost in the commercial vehicle market development, and meet the requirements of large-scale automated production mode.

Claims

1. A control assembly for a new energy vehicle, characterized in that: It includes a box body (1). A heat dissipation water channel is arranged inside the box body (1). The heat dissipation water channel divides the internal space of the box body (1) into an upper cavity and a lower cavity. Inside the upper cavity, two HPD drive modules (14), two DCAC drive modules (17), a main contactor (18), three high-voltage distribution contactors (20), a high-voltage distribution fuse (21), a control board (22), a DC bus bar (27), a composite bus bar (28), and an AC bus bar (29) are respectively arranged. A drive board (15) is arranged on each HPD drive module (14), and a board-mounted current sensor (16) is arranged on the drive board (15). A magnetic ring (31) and a Y-capacitor board (32) are respectively arranged on the DC bus bar (27). Two capacitors (25) are arranged inside the lower cavity. The positive pole of the DC bus bar (27) is connected to one end of the main contactor (18), and the negative pole of the DC bus bar (27) is connected to the composite bus bar (28). The composite bus bar (28) is respectively connected to the other end of the main contactor (18), two DCAC drive modules (17), two HPD drive modules (14), and two capacitors (25). The AC bus bar (29) is connected to the HPD drive module (14); the high-voltage distribution contactor (20) is respectively connected to the positive and negative poles of the high-voltage distribution fuse (21) and the DC bus bar (27) through the composite bus bar (28). The control board (22) is connected to the HPD drive module (14) and the DCAC drive module (17) through wire harnesses respectively. The metal pins of the capacitor (25) are respectively connected to the HPD drive module (14) and the composite bus bar (28).

2. The control assembly for a new energy vehicle according to claim 1, characterized in that: A quick-connect type high-voltage DC input interface (10) and a dual-channel quick-connect type AC output interface (11) are respectively arranged on the lower side of the front part of the box body (1). The quick-connect type high-voltage DC input interface (10) is connected to the positive and negative poles of the DC bus bar (27), and the dual-channel quick-connect type AC output interface (11) is connected to the AC bus bar (29).

3. The control assembly for a new energy vehicle according to claim 1, characterized in that: Coolant inlet and outlet water pipes (6), a dual-channel DCAC output interface (7), and a three-channel high-voltage distribution external interface (8) are respectively arranged on one side part of the box body (1). The coolant inlet and outlet water pipes (6) are communicated with the heat dissipation water channel. The DCAC drive module (17) is connected to the DCAC output interface (7) through a wire harness. The high-voltage distribution contactor (20) is connected to the high-voltage distribution external interface (8) through a wire harness.

4. The control assembly for a new energy vehicle according to claim 3, characterized in that: A micro switch (33) is arranged inside the box body (1). The micro switch (33) is connected to the DCAC output interface (7), the high-voltage distribution external interface (8), and the control board (22) through wire harnesses respectively.

5. The control assembly for a new energy vehicle according to claim 1, characterized in that: A DCDC module (26) is arranged inside the described box body (1). The DCDC module (26) is located in the lower cavity. The DCDC module (26) is connected to the positive and negative poles of the DC busbar (27) and the high-voltage distribution fuse (21) respectively through wire harnesses.

6. A control assembly for a new energy vehicle as described in claim 5, characterized in that: A DCDC output interface (9) is arranged on the side of the described box body (1). The DCDC module (26) is connected to the DCDC output interface (9) through a composite busbar (28).

7. A control assembly for a new energy vehicle as described in claim 3, characterized in that: A waterproof breathable valve and a low-voltage control interface (13) are respectively arranged on the other side of the described box body (1). The low-voltage control interface (13) is connected to the control board (22) through a wire harness.

8. A control assembly for a new energy vehicle as described in claim 1, characterized in that: A pre-charge contactor (19) and a distribution board (23) are respectively arranged inside the described box body (1). The distribution board (23) is connected to the high-voltage distribution contactor (20), the main contactor (18), the pre-charge contactor (19) and the control board (22) respectively through wire harnesses.

9. A control assembly for a new energy vehicle as described in claim 1, characterized in that: An upper cover plate (2) is arranged on the upper part of the described box body (1), and a lower cover plate (3) is arranged on the lower part of the box body (1).

10. A control assembly for a new energy vehicle as described in any one of claims 1-9, characterized in that: A support plate (24) is arranged in the upper cavity. The high-voltage distribution fuse (21) is installed on the side of the support plate (24), and the control board (22) is installed on the upper part of the support plate (24).

Images