Printed circuit board assembly for measuring the battery current of a battery-powered vehicle

Abstract

The present invention relates to a printed circuit board assembly for measuring the battery current of a battery-powered vehicle, wherein the printed circuit board assembly comprises the following parts: a main board having one or more plug-in mechanisms for electrically connecting the main board to a control device in a wired manner; at least one measuring board having a current measuring resistor for detecting the battery current of the battery of the battery-powered vehicle, wherein the at least one measuring board is mounted on the main board through a plurality of metal pads, and wherein the current measuring resistor is connected to the one or more plug-in mechanisms through an electrical connection mechanism; wherein the at least one measuring board can be mechanically and electrically connected to the bus bar of the battery to detect the voltage drop across the current measuring resistor and transfer it to the control device via the one or more plug-in mechanisms of the main board.

Description

Field of the Invention

[0001] The present invention relates to the field of battery - powered vehicles, in particular electric vehicles. The present invention particularly relates to a printed circuit board assembly and a method for measuring the battery current of a battery - powered vehicle. The present invention also relates to a switch cabinet for monitoring the battery of a battery - powered vehicle. Background Art

[0002] Current battery switch cabinets or HV boxes for monitoring and switching on / off vehicle batteries have a number of printed circuit boards or individual components, which are connected to respective plug - in mechanisms to perform different tasks. Thus, one printed circuit board is responsible for communicating with the main control unit, another printed circuit board is responsible for measuring the current of the busbar from the battery to the vehicle electrical components, and yet another printed circuit board is responsible for measuring the current of another busbar, etc. This results in complex installation of these individual components and assembly within the HV box. The various different plug - in mechanisms of the individual components may be prone to installation errors. In addition, the degree of automation of the installation of individual components is poor and mostly requires manual execution. Summary of the Invention

[0003] Therefore, the object of the present invention is to simplify an advantageous concept and provide a reliable installation of a battery switch cabinet or HV box, in particular a simplified installation concept for an HV box for precisely monitoring the battery current here.

[0004] This object is achieved by the subject matter of the independent claims. Advantageous refinements of the invention are specified in the dependent claims, the description and the drawings.

[0005] The inventive solution is based on integrating a plurality of individual components into a backplane. Components that were previously separate are combined into a central backplane with an integral shunt resistor. Thus, a reduction is achieved to only one central backplane with an integral shunt resistor. Therefore, the additional plug - in of the existing shunt resistor components can be omitted, and for this purpose, additional plugs are no longer required. This solution can be manufactured significantly more inexpensively and more reliably because potential error sources can be avoided.

[0006] Another concept of the present invention is based on the brazing connection surface of the shunt resistor component being rasterized into small individual areas or rows and columns, so as to allow more precise measurement of the battery current. Thus, so - called measurement point "drift" is prevented and because the pads are smaller, no or significantly smaller air inclusions (voids) occur during the manufacture of the brazing connection.

[0007] According to a first aspect, the above task is accomplished by a printed circuit board assembly for measuring the battery current of a battery-powered vehicle, wherein the printed circuit board assembly comprises the following components: a main board having one or more plug-in mechanisms for electrically connecting the main board to a control device under wire control; at least one measuring board having a current measuring resistor for measuring the battery current of the battery of the battery-powered vehicle, wherein the at least one measuring board is mounted on the main board by a plurality of metal pads, and wherein the current measuring resistor is connected to the one or more plug-in mechanisms by an electrical connection mechanism; wherein the at least one measuring board can be electromechanically connected to the bus bar of the battery to measure the voltage drop across the current measuring resistor and transfer the voltage drop to the control device via the one or more plug-in mechanisms of the main board.

[0008] This printed circuit board assembly, hereinafter also referred to as a "backplane", offers the technical advantage of integrating a plurality of individual components into a single backplane. Thus, the main board together with one or more measuring boards is realized by means of the same backplane, i.e., the printed circuit board assembly. Hitherto separate components, namely the main board and one or more measuring boards, are combined into a central backplane with an integral parallel resistor, i.e., the current measuring resistor. Thus, it is achieved that only a single central backplane with an integral parallel resistor or current measuring resistor remains, i.e., the printed circuit board assembly. Thus, the additional plugging of the existing parallel resistor components, i.e., the measuring boards, can be dispensed with, and for this purpose no additional plugs are required either. Compared with plugging together various individual components, this printed circuit board assembly can be manufactured significantly more cheaply and more reliably, because pre-assembled components avoid potential error sources during installation.

[0009] According to an embodiment of the printed circuit board assembly, the current measuring resistor is designed as a measuring parallel resistor, which is designed to measure the battery current based on the voltage drop across the measuring parallel resistor and the nominal resistance of the measuring parallel resistor.

[0010] This measuring parallel resistor offers the following advantages, namely, by measuring the measuring parallel resistor, a parallel current path is provided, wherein the battery current to be measured can be determined very precisely by ascertaining the shunt current flowing through the measuring parallel resistor.

[0011] The measuring parallel resistor is an accurate resistor in parallel, which is used to measure alternating current and direct current in such a way that it forms a low-ohm path. The parallel resistor with low resistance produces only a small voltage drop because it inputs less energy into the process. With Ohm's law, the voltage in the parallel resistor is measured and used to calculate the current flow in amperes.

[0012] According to an embodiment of the printed circuit board assembly, the at least one measuring board is soldered, bonded or welded to the main board by these metal pads.

[0013] This provides the following advantages, namely, a fixed connection is produced between the terminals of the measurement board and the terminals of the main board, so that manual plugging is no longer required, and thus errors can be reduced.

[0014] According to one embodiment of the printed circuit board assembly, the at least one measurement board can be connected to the bus bar of the battery by a bolt connection.

[0015] This provides the following advantages, namely, the measurement board can measure the battery current as in a high-voltage battery commonly used to drive an electric vehicle. A fixed connection to the corresponding contacts of the measurement board is achieved by a threaded connection, which ensures safe current conduction.

[0016] According to one embodiment of the printed circuit board assembly, these metal pads are arranged on the at least one measurement board in the form of a grid surface.

[0017] This obtains the following advantages, namely, such a grid surface can be efficiently manufactured and there are fewer air inclusions in the contact terminal surface. Multiple small contact surfaces can be manufactured better and more reliably than a single large contact surface.

[0018] According to one embodiment of the printed circuit board assembly, these metal pads are arranged on the at least one measurement board in the form of a grid.

[0019] By the arrangement in the form of a grid, a prescribed tap can be provided and the measurement accuracy is thus improved.

[0020] According to one embodiment of the printed circuit board assembly, the grid consists of two grid surfaces, and the current measurement resistor is arranged between the grid surfaces.

[0021] This provides the following technical advantages, namely, the measurement can be carried out very precisely based on the geometry of the arrangement.

[0022] According to one embodiment of the printed circuit board assembly, these metal pads are designed as square metal gaskets.

[0023] This provides the following advantages, namely, contact resistances of the same size can be efficiently processed on both sides of the terminal, that is, on the two grid surfaces.

[0024] According to one embodiment of the printed circuit board assembly, the current measurement resistor is designed as a resistance measurement chip arranged between two grid surfaces.

[0025] This provides the following advantages, namely, such a resistor can be processed as an accurate resistor in the form of a measurement chip, which ensures high precision in battery current measurement. The resistance measurement chip can be designed, for example, as a manganin measurement chip providing high measurement precision.

[0026] According to an embodiment of the printed circuit board assembly, these metal pads of the two grid surfaces are symmetrically arranged on the at least one measurement board with respect to the resistance measurement chip.

[0027] This provides the advantage that such a symmetric arrangement allows for high measurement accuracy in battery current measurement.

[0028] According to an embodiment of the printed circuit board assembly, each of the two grid surfaces has a measurement tap, which is mounted at the center of the respective grid surface.

[0029] This predefined centered measurement tap provides high measurement accuracy during battery current measurement. Additionally, so-called "differential pair routing" can be employed to suppress possible interference on the lines.

[0030] According to an embodiment of the printed circuit board assembly, the respective measurement taps of the two grid surfaces are formed in the form of square metal pads, the area of which is larger than the area of the meshed metal pads.

[0031] This provides the advantage that the measurement taps can be well contacted to transmit the voltage signal applied thereto to the control device. The voltage signal can then be converted into a digital voltage signal in the control device by means of an A / D converter and determined according to Ohm's law of the battery current based on the current nominal resistance of the resistance measurement chip.

[0032] According to an embodiment of the printed circuit board assembly, the printed circuit board assembly includes a calibration data memory, which is mounted on the main board and designed to store data for calibrating the current measurement resistance of at least one measurement board.

[0033] This provides the advantage that the current measurement resistance can be calibrated based on this data, so that the measurement voltage on the current measurement resistance can be accurately converted into battery current. The data for calibrating the current measurement resistance can, for example, include the resistance value of the current measurement resistance based on, for example, the ambient temperature.

[0034] According to an embodiment of the printed circuit board assembly, the main board has a main path and two sub-paths branching off from the main path, and a measurement board is respectively mounted at the end of each sub-path.

[0035] This provides the advantage that the described embodiment is well-suited for connection to two current measurement rails without the two busbars contacting each other. Therefore, two different currents with high current intensities can be measured simultaneously, for example, the battery current flowing to the electrical consumers in the vehicle and the current flowing back to the battery. Or, the current of a second battery can be measured, for example, the current of the main battery and the current of a redundantly designed battery.

[0036] According to an embodiment of the printed circuit board assembly, the two sub-paths extend parallel to each other and have different lengths.

[0037] This provides the advantage that two busbars can be connected to a respective secondary path. Since the lengths of the two secondary paths are different, the two busbars can extend parallel to each other without further influencing each other.

[0038] According to a second aspect, the above task is accomplished by a switch cabinet for monitoring the battery of a battery-powered vehicle, having: a busbar connectable to the battery of the battery-powered vehicle; a printed circuit board assembly for measuring the battery current of the battery-powered vehicle according to the above first aspect, wherein the at least one measuring board is electromechanically connected to the busbar.

[0039] Such a switch cabinet provides the following technical advantages: multiple individual components can be integrated into the same backplane that can be placed inside the switch cabinet. Thus, it is achieved that there is only one central backplane with an integral parallel resistor or current measuring resistor left, namely the printed circuit board assembly, which can be simply installed inside the switch cabinet. The additional plugging in of the existing parallel resistor components in the switch cabinet manufacturing, namely the measuring boards, can be dispensed with, and for this reason, no additional plugs are required either. The switch cabinet can thus be simply manufactured, for example by means of automated manufacturing, and can be manufactured significantly more inexpensively compared to the plugging and assembling of the various individual components. The switch cabinet is also more reliable because potential error sources during installation can be avoided due to the components already being assembled.

[0040] According to a third aspect, the above task is accomplished by a method for measuring the battery current of a battery-powered vehicle using the printed circuit board assembly according to the above first aspect, wherein the method comprises the following steps: electrically connecting the main board to a control device by inserting the wires of the control device into one or more plugging mechanisms on the main board; electromechanically connecting the at least one measuring board to the busbar of the battery; detecting the voltage drop across the current measuring resistor of the at least one measuring board; and transferring the detected voltage drop to the control device via one or more plugging mechanisms of the main board to determine the battery current.

[0041] This method provides the same advantages as the above printed circuit board assembly. That is, compared to the plugging and combination of various individual components, the printed circuit board assembly can be manufactured significantly more inexpensively and more reliably because potential error sources during installation can be avoided due to the components already being assembled.

[0042] According to a fourth aspect, the above task is accomplished by a computer program with program code for executing the method according to the third aspect on a computer.

[0043] Thereby, the following technical advantage is obtained: the computer program can be simply executed on a controller, for example a microcontroller. Description of the Drawings

[0044] The present invention will be described in detail below in conjunction with embodiments and figures, where:

[0045] Figure 1 a shows a front - side schematic view of a printed - circuit - board assembly 100 for measuring the battery current of a battery - powered vehicle according to one embodiment;

[0046] Figure 1 b shows a back - side schematic view of the printed - circuit - board assembly 100 according to one embodiment;

[0047] Figure 2 shows a schematic view of a measurement board 102a according to one embodiment;

[0048] Figure 3 shows a front - side view of the measurement board 102a according to one embodiment;

[0049] Figure 4 shows a three - dimensional back - side view of the printed - circuit - board assembly 100 according to one embodiment;

[0050] Figure 5 shows a view of a part of a switch box 500 for monitoring the battery of a battery - powered vehicle, in which there is a printed - circuit - board assembly 100;

[0051] Figure 6 shows a schematic view of a method for measuring the battery current of a battery - powered vehicle. Detailed implementation manners

[0052] The figures are only schematic diagrams and are only used to explain the present invention. Identical or functionally identical components are always provided with the same reference numerals.

[0053] In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in these drawings, specific implementation manners in which the present invention can be implemented are shown by way of illustration. Obviously, other implementation manners can also be adopted and structural or logical changes can be made without departing from the scope of the present invention. Therefore, the following detailed description should not be construed in a limiting sense. In addition, obviously, the features of the various different embodiments described herein can be combined with each other unless otherwise specifically stated.

[0054] The aspects and implementation manners are described with reference to the figures, where the same reference numerals generally refer to the same components. In the following description, many detailed details are shown for the purpose of explanation to facilitate a detailed understanding of one or more aspects of the present invention. However, it may be obvious to those skilled in the art that one or more aspects or implementation manners with fewer specific details can be implemented. In other cases, known structures and elements are shown in schematic form to simplify the description of one or more aspects or implementation manners. Obviously, other implementation manners can be utilized and structural or logical changes can be made without departing from the concept of the present invention.

[0055] This document describes a printed circuit board assembly. A printed circuit board assembly in the sense of this document is a fixed assembly composed of different printed circuit boards or boards that are fixedly connected to each other, so that the plugging or wiring of individual components can be omitted. The printed circuit board assembly can thus be simply manufactured by machine and can already be pre-processed. The individual printed circuit boards and boards can be connected to each other by different connection techniques, for example by soldering, welding, crimping, bonding or other techniques.

[0056] The measurement of parallel resistors or low-ohm precision resistors is described herein. A parallel resistor for measurement is a precision resistor in parallel, which is used to measure alternating current and direct current, because it forms a low-ohm path. This parallel resistor with low resistance, also known as an ammeter shunt resistor or current shunt resistor, only produces a small voltage drop, because it inputs a small amount of energy into the process. With Ohm's law, the voltage in the parallel resistor is measured and used to calculate the current flow in amperes. A resistor with an accurately known resistance, such as a manganin resistor, is connected in parallel with the ammeter. The current is then shunted, only a small amount of current flows through the ammeter, and the actual current intensity can be directly measured. Multiple parameters are important for the parallel resistor specification. The parallel resistor has a maximum rated current. The resistance value is derived from the voltage drop at the maximum rated current. Other important parameters are the resistance error, the temperature coefficient and the nominal power. The nominal power indicates the amount of electric power that the resistor can conduct away at a certain ambient temperature without damaging or changing the resistor parameters. The power generated can be calculated using Joule's law.

[0057] Figure 1 Figure a shows a front-side schematic view of a printed circuit board assembly 100 for measuring the battery current of a battery-powered vehicle according to an embodiment. Figure 1 Figure b shows a back-side schematic view of the printed circuit board assembly 100.

[0058] The printed circuit board assembly 100 includes a main board 101 and one or more measurement boards, which are two measurement boards 102a and 102b in this embodiment.

[0059] The main board 101 has one or more plug-in mechanisms 107 for electrically connecting the main board 101 to a control device, such as the main controller of a battery-powered vehicle, on which most control tasks are performed, in a wired manner.

[0060] Each measurement board 102a, 102b has a corresponding current measurement resistor 103a, 103b for detecting the battery current of the battery of the battery-powered vehicle. The respective measurement boards 102a, 102b are mounted on the main board 101 through a plurality of metal pads 104a, 104b. The respective current measurement resistors 103a, 103b are connected to the one or more plug-in mechanisms 107 through electrical connection mechanisms.

[0061] Via the electrical connection mechanism, the measurement taps of the respective current measurement resistors 103a, 103b can be switched over and guided to the control device via the plug-in mechanism, on which, for example, the current measurement can be determined based on the known voltage drop across the current measurement resistor.

[0062] The respective measurement boards 102a, 102b can be electromechanically connected to the busbars of the battery to detect the voltage drops across the respective current measurement resistors 103a, 103b and transferred to the control device via one or more plug-in mechanisms 107 of the main board 101.

[0063] The current measurement resistors 103a, 103b can be designed as measurement shunt resistors, which are designed to detect the respective battery currents based on the voltage drop across the measurement shunt resistors 103a, 103b and the nominal resistances of the measurement shunt resistors 103a, 103b.

[0064] The at least one measurement board 102a, 102b can be soldered, glued or welded to the main board 101 via these metal pads 104a, 104b.

[0065] For example, the at least one measurement board 102a, 102b can be connected to the busbars 501a, 501b of the battery by means of a bolted connection.

[0066] These metal pads 104a, 104b can be arranged on the at least one measurement board 102a, 102b in the form of a grid surface, just as, for example, in Figure 2 and Figure 3 is shown in detail.

[0067] These metal pads 104a, 104b can be arranged on the at least one measurement board 102a, 102b in the form of grids 301a, 301b, just as, for example, in Figure 2 and Figure 3 is shown in detail.

[0068] The grids 301a, 301b can consist of two grid surfaces 301a, 301b, between which the current measurement resistor 303 is arranged, just as, for example, in Figure 3 is shown in detail.

[0069] These metal pads 104a, 104b can be designed as square and / or circular metal pads, just as, for example, in Figure 3 is shown in detail.

[0070] The current measurement resistors 103a, 103b can be designed as resistance measurement chips 303, which are arranged between two grid surfaces 301a, 301b.

[0071] The resistance measuring element can for example be made of manganin. Manganin (CuMn12Ni) is a copper-nickel-manganese alloy consisting of 82 - 84% copper, 12 - 15% manganese and 2 - 4% nickel by mass content. It is a resistance alloy with a low resistance temperature correlation. The temperature coefficient is approximately α = 0.02·10 -3 K -1 .

[0072] The current measuring resistors 103a, 103b can be designed as low-ohm measuring resistors, for example with a resistance of approximately 50 μOhm. Thus, currents in the range of 2000 - 3000 amperes can be measured, such as those occurring for example in the high-voltage battery of an electric vehicle.

[0073] These metal connection pads 104a, 104b of the two grid surfaces 301a and 301b can be arranged symmetrically with respect to the resistance measuring element 303 (longitudinal axis of the resistance measuring element) on at least one measuring board 102a, 102b.

[0074] The two grid surfaces 301a, 301b can each have a measuring tap 105a, which is arranged at the center of the respective grid surface 301a, 301b, as shown in detail in Figure 3 .

[0075] The respective measuring taps 105a of the two grid surfaces 301a, 301b can be formed in the form of square metal pads, the area of which is larger than the area of the meshed metal connection pads 104a, 104b, as shown in detail in Figure 3 .

[0076] The printed circuit board assembly 100 can also include a correction data memory, which is arranged on the main board 101 and is designed to store data for correcting the current measuring resistors 103a, 103b of the at least one measuring board 102a, 102b. Such a correction data memory can be designed as an EPROM memory with low storage capacity. The memory can for example be arranged on the back of the main board 101 next to the plug-in mechanism 107, as shown in Figure 1 b.

[0077] In the example of Figure 1 a and 1b, the main board 101 has a main path and two secondary paths branching off from the main path, and at the ends of the secondary paths, a measuring board 102a, 102b is respectively mounted. Thus, two parallel extending busbars can be screwed onto the two measuring boards, as shown in detail in Figure 5 .

[0078] The two sub-paths can extend towards each other and have different lengths from each other. Thus, the two busbars do not intersect. They can extend in a plane and still be separated from each other. The printed circuit board assembly can thus be arranged substantially in a plane, and it can thus be manufactured in a space-saving manner.

[0079] Figure 2 Schematic view showing a measurement board 102a according to an embodiment. The measurement board 102a corresponds to one of the measurement boards 102a or 102b as shown and described above. Figure 1 shown and described.

[0080] The measurement board 102a has a current measurement resistor 103a for detecting the battery current of the battery of an electric vehicle. The measurement board 102a is mounted on the main board 101 by means of a plurality of metal pads 104a. The current measurement resistor 103a is connected to one or more plug-in mechanisms 107 on the main board 101 by an electrical connection mechanism, as Figure 1 shown in b.

[0081] By means of the electrical connection mechanism, two measurement taps of the current measurement resistor 103a mounted at the center of the measurement board 102a are transferred and guided to the control device through the plug-in mechanism, where, for example, the current measurement can be determined based on the detected voltage drop across the current measurement resistor 103a.

[0082] The measurement board 102a can be connected to the busbar of the battery on the back side, for example by means of a stable threaded connection, in order to detect the voltage drop across the current measurement resistor 103a and transfer it to the control device via the plug-in mechanism 107 of the main board 101.

[0083] Figure 3 Front view showing a measurement board 102a according to an embodiment.

[0084] The measurement board 102a can be designed to measure a parallel resistor, whereby the battery current can be detected based on the voltage drop across the measurement parallel resistor 103a and the nominal resistance of the measurement parallel resistor 103a.

[0085] The measurement board 102a has a plurality of metal pads 104a, which can be soldered, glued or welded to the main board 101. A firm connection between the measurement board 102a and the main board 101 is thus obtained.

[0086] The measurement board 102a can be connected to the busbar of the battery by a threaded connection, as Figure 5 shown in detail in.

[0087] These metal pads 104a can be arranged on the measurement board 102a in a grid pattern or grid form, as Figure 3 can be clearly seen in.

[0088] These metal pads 104a, 104b can be arranged in the form of grids 301a, 301b on at least one measuring plate 102a, 102b, just as, for example, is shown in detail in Figure 2 and Figure 3 In this grid design, the formation of spaces (voids) inside or below the gasket is significantly reduced. For example, the "formation of voids", i.e., the formation of spaces, can be reduced by up to 20% or more.

[0089] The grid can consist of two grid surfaces 301a, 301b, between which the current measuring resistor 303 is arranged. These metal pads 104a can be designed as square and / or round metal gaskets.

[0090] The current measuring resistor 103a can be designed as a resistance measuring chip 303, which is arranged between two grid surfaces 301a and 301b. The current measuring resistor 103a can be designed as a low-ohm measuring resistor, for example, having a resistance of about 50 μOhm.

[0091] These metal pads 104a, 104b of the two grid surfaces 301a, 301b can be arranged symmetrically on the measuring plate 102a with respect to the resistance measuring chip 303, i.e., with respect to its longitudinal axis.

[0092] Each of the two grid surfaces 301a, 301b can have a measuring tap 105a, which is arranged at the center of the respective grid surface 301a, 301b. Thus, a prescribed centered measuring tap is achieved. "Differential pair routing" can be used.

[0093] Differential PCB routing or "differential pair routing" is a layout technique that is used to provide a symmetric transmission system that can transmit differential (identical but opposite) signals via a circuit board. Each of the two signal lines is terminated at the receiving side with its own waveform resistor in a prescribed manner.

[0094] The respective measuring taps 105a of the two grid surfaces 301a, 301b can be formed in the form of square metal gaskets, the area of which is larger than the area of the meshed metal pads 104a, 104b.

[0095] Figure 4 A three-dimensional view of the back side of a printed circuit board assembly 100 according to an embodiment is shown.

[0096] The printed circuit board assembly 100 includes a main board 101 having one or more plug-in mechanisms 107 for electrically connecting the main board 101 to a control device in a wire-controlled manner, and at least one measurement board having current measurement resistors 103a, 103b for measuring the battery current of a battery of a battery-powered vehicle. In this embodiment, there are two measurement boards 102a, 102b.

[0097] The at least one measurement board 102a, 102b is mounted on the main board 101 through a plurality of metal pads 104a, 104b. The current measurement resistors 103a, 103b are connected to the one or more plug-in mechanisms 107 through an electrical connection mechanism ( Figure 4 not shown).

[0098] The at least one measurement board 102a, 102b can be mechanically and electrically connected to a battery busbar to measure the voltage drop across the current measurement resistors 103a, 103b and transfer it to a control device through the one or more plug-in mechanisms 107 of the main board 101.

[0099] Figure 5 A view showing a part of a switch box 500 for monitoring a battery of a battery-powered vehicle, in which the printed circuit board assembly 100 is located.

[0100] The switch box 500 is the central controller of the sensor device in the vehicle. It is used to measure and monitor the battery current of a battery, such as a high-voltage battery in the vehicle. When there is an overcurrent or a short circuit, the power supply line must be separated from the battery to avoid vehicle damage.

[0101] The switch box 500 includes busbars 501a, 501b that can be connected to the battery of the battery-powered vehicle. The switch box 500 includes a printed circuit board assembly 100 for measuring the battery current of the battery-powered vehicle, as shown above with respect to Figures 1 - 4 shown. The at least one measurement board 102a, 102b is mechanically and electrically connected to the busbar.

[0102] The printed circuit board assembly 100 for measuring the battery current of a battery-powered vehicle includes: a main board 101 having one or more plug-in mechanisms 107 for electrically connecting the main board 101 to a control device, such as a vehicle main controller, in a wire-controlled manner; at least one measurement board 102a, 102b having current measurement resistors 103a, 103b for measuring the battery current of the battery, wherein the at least one measurement board 102a, 102b is mounted on the main board 101 through a plurality of metal pads 104a, 104b, as shown above with respect to Figures 1 - 4As shown in detail, and wherein the current measuring resistors 103a, 103b are connected to one or more plug-in mechanisms 107 by an electrical connection mechanism. At least one measuring board 102a, 102b is electromechanically connected to the busbars 501a, 501b of the battery to detect the voltage drop across the current measuring resistors 103a, 103b and transfer it to the control device through one or more plug-in mechanisms 107 of the main board 101.

[0103] The switch cabinet 500 includes a protector 502 in this example, and when a short circuit or overcurrent event is determined, the protector can disconnect the current flow towards or from the battery.

[0104] Figure 6 A schematic diagram showing a method 600 for measuring the battery current of a battery-powered vehicle is shown.

[0105] Method 600 includes: electrically connecting 601 the main board 101 to the control device by inserting the wires of the control device into one or more plug-in mechanisms 107 on the main board 101, just as for example in Figures 1 - 5 shown in detail.

[0106] Method 600 includes: electromechanically connecting 602 at least one measuring board 102a, 102b to the busbars of the battery, just as for example with respect to Figures 1 - 5 described in detail.

[0107] Method 600 includes: detecting 603 the voltage drop across the current measuring resistors 103a, 103b of at least one measuring board 102a, 102b, just as for example described in detail with respect to 1-5.

[0108] Method 600 includes: transferring 604 the detected voltage drop to the control device through one or more plug-in mechanisms 107 of the main board 101 to determine the battery current, just as for example with respect to Figures 1 - 5 described in detail.

[0109] List of reference numerals

[0110] 100 Printed circuit board assembly

[0111] 101 Main board

[0112] 102a First measuring board

[0113] 102b Second measuring board

[0114] 103a First current measuring resistor

[0115] 103b Second current measuring resistor

[0116] 104a, 104b Metal pads

[0117] 107 Plugging mechanism

[0118] 301a First grid surface (left)

[0119] 301b Second grid surface (right)

[0120] 303 Resistance measuring piece

[0121] 500 Switch box

[0122] 501a First bus bar

[0123] 501b Second bus bar

[0124] 600 Method for measuring the battery current of a battery-powered vehicle

[0125] 601 First method step

[0126] 602 Second method step

[0127] 603 Third method step

[0128] 604 Fourth method step

Claims

1. A printed circuit board assembly for measuring the battery current of a battery-powered vehicle, wherein, The printed circuit board assembly comprises the following parts: A main board having one or more plug-in mechanisms for electrically connecting the main board to a control device in a wired manner; At least one measurement board having a current measurement resistor for measuring the battery current of the battery of the battery-powered vehicle, wherein the at least one measurement board is mounted on the main board by a plurality of metal pads, and wherein the current measurement resistor is connected to the one or more plug-in mechanisms by an electrical connection mechanism; Wherein the at least one measurement board can be electromechanically connected to the bus bar of the battery to measure the voltage drop across the current measurement resistor and transfer it to the control device via the one or more plug-in mechanisms of the main board; Wherein the plurality of metal pads are arranged in a grid plane on the at least one measurement board.

2. The printed circuit board assembly according to claim 1, wherein, The current measurement resistor is designed as a shunt resistor and is designed to measure the battery current based on the voltage drop across the shunt resistor and based on the nominal resistance of the shunt resistor.

3. The printed circuit board assembly according to claim 1 or 2, wherein The at least one measurement board is soldered, bonded or welded to the main board by the plurality of metal pads.

4. The printed circuit board assembly according to claim 1 or 2, wherein The at least one measurement board can be connected to the bus bar of the battery by a threaded connection mechanism.

5. The printed circuit board assembly according to claim 1, wherein, The plurality of metal pads are arranged in a grid on the at least one measurement board.

6. The printed circuit board assembly according to claim 5, wherein, The grid consists of two grid planes, and the current measurement resistor is arranged between the grid planes.

7. The printed circuit board assembly according to claim 6, wherein, The plurality of metal pads are designed as square metal gaskets.

8. The printed circuit board assembly according to claim 6 or 7, wherein, The current measurement resistor is designed as a resistance measurement chip arranged between the two grid planes.

9. The printed circuit board assembly according to claim 8, wherein, The plurality of metal pads of the two grid planes are symmetrically arranged on the at least one measurement board with respect to the resistance measurement chip.

10. The printed circuit board assembly according to claim 6, 7 or 9, wherein, Each of the two grid planes has a measurement tap arranged at the center of the respective grid plane.

11. The printed circuit board assembly according to claim 10, wherein, The respective measurement taps of the two grid planes are formed in the form of square metal gaskets, and the area they contain is larger than that of the meshed metal pads.

12. The printed circuit board assembly according to claim 1 or 2, having a calibration data memory which is mounted on the main board and is designed to store data for calibrating the current measurement resistor of the at least one measurement board.

13. The printed circuit board assembly according to claim 1 or 2, wherein, The main board has a main path and two sub-paths branched from the main path, and a measurement board is respectively arranged at the ends thereof.

14. The printed circuit board assembly according to claim 13, wherein, The two sub-paths extend parallel to each other and have different lengths from each other.

15. A switch box for monitoring the battery of a battery-powered vehicle, having: A bus bar capable of being connected to the battery of the battery-powered vehicle, and The printed circuit board assembly according to any one of claims 1 to 13 for measuring the battery current of the battery of the battery-powered vehicle, Among them, The at least one measurement board is electromechanically connected to the bus bar.

16. A method for measuring the battery current of a battery-powered vehicle by means of a printed circuit board assembly according to one of claims 1 to 13, wherein, The method has the following steps: Electrically connecting the main board to the control device by inserting the wires of the control device into one or more plug-in mechanisms on the main board; Electromechanically connecting the at least one measurement board to the bus bar of the battery; Measuring the voltage drop across the current measurement resistor of the at least one measurement board; and Transferring the measured voltage drop to the control device via the one or more plug-in mechanisms of the main board to determine the battery current.

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