A new type of wireless BDU without bolt connection

Abstract

The present invention discloses a novel wireless bundled BDU without bolt connection, which relates to the technical field of battery high-voltage power distribution control unit, including a housing, and a relay and a safety device located in the housing, and a first copper busbar located between the relay and the safety device, wherein a raised positioning pin is provided on the lower end of the relay, and a first positioning hole is provided on the contact blade of the safety device, and the first copper busbar includes a first connection end and a second connection end, wherein a positioning pin hole matching the positioning pin is provided on the first connection end, and the first connection end is welded and fixed to the relay, and a second positioning hole matching the first positioning hole is provided on the second connection end, and the second connection end is welded and fixed to the safety device. The entire BDU of the present application has no bolts and no wireless bundles, and the structure is beautiful, and the BDU is produced and tested using an automated production line, and the process flow is simple.

Description

Technical Field

[0001] The present invention relates to the technical field of battery high-voltage power distribution control units, and in particular to a novel wireless bundled BDU without bolt connection. Background Art

[0002] At present, BDU (Battery Disconnect Unit), EDM (Electric Drive Assembly), E-BOX (Battery Connection Box) and other devices generally use bolts or nuts to fix copper bars, relays, fuses, shunts and other devices; at the same time, the existing BDU, EDM, E-BOX and other BDU wireless bundles all use bolts or nuts to fix copper sheets, or use copper sheets and plastic parts to be molded together and then installed with bolts or nuts. In addition, existing relays all use contact knives / heads with threaded holes, and overcurrent large fuses, shunts, etc. all use large mounting holes.

[0003] Therefore, how to realize wireless bundled BDU without the need for bolts or nuts to fix it has become a problem that needs to be solved urgently. Summary of the invention

[0004] The present application provides a novel wireless bundled BDU without bolt connection. There are no bolts or wireless bundles in the entire BDU, and the structure is beautiful. The BDU is produced and tested using an automated production line, and the process flow is simple.

[0005] In a first aspect, an embodiment of the present application provides a novel wireless bundled BDU without bolt connection, characterized in that the novel wireless bundled BDU without bolt connection includes a housing, and located inside the housing:

[0006] A relay, wherein a protruding positioning pin is provided on the lower end of the relay;

[0007] A safety device, wherein a first positioning hole is provided on the contact blade of the safety device;

[0008] A first copper busbar is located between the relay and the safety device, the first copper busbar includes a first connecting end and a second connecting end, the first connecting end is provided with a positioning pin hole matching with the positioning pin, and the first connecting end is welded and fixed to the relay, the second connecting end is provided with a second positioning hole matching with the first positioning hole, and the second connecting end is welded and fixed to the safety device.

[0009] In combination with the first aspect, in one embodiment, a third positioning hole is further provided on the first connection end for achieving positioning when the first connection end and the relay are welded and fixed, and the second positioning hole cooperates with the first positioning hole to achieve positioning when the second connection end and the fuse are welded and fixed.

[0010] In combination with the first aspect, in one implementation, the first copper bar is integrally injection-molded with the housing to achieve positioning of the first copper bar.

[0011] In combination with the first aspect, in one embodiment, the new type of bolt-free wireless bundled BDU also includes a shunt located on one side of the relay, a fourth positioning hole is provided on the contact blade of the shunt, a second copper bus is also provided between the relay and the shunt, a fifth positioning hole matching the fourth positioning hole is provided on one end of the second copper bus for connecting the shunt, and the second copper bus is welded and fixed to the shunt.

[0012] In combination with the first aspect, in one implementation, the second copper bar is integrally injection-molded with the housing to achieve positioning of the second copper bar.

[0013] In combination with the first aspect, in one embodiment, the new bolt-free wireless bundled BDU also includes a PCB board located at the top of the relay, and a first nickel sheet is provided between the relay and the PCB board, one end of the first nickel sheet is welded and fixed to the low-voltage control coil of the relay, and the other end is welded and fixed to the PCB board, and the first nickel sheet is provided with a sixth positioning hole for positioning the first nickel sheet and the low-voltage control coil during welding.

[0014] In combination with the first aspect, in one embodiment, a riveted copper column or a riveted aluminum column is also welded on the overcurrent copper busbar of the wireless bundled BDU, one end of the riveted copper column or the riveted aluminum column is welded and fixed to the overcurrent copper busbar, and the other end is welded and fixed to the second nickel sheet welded on the PCB board, so that when voltage sampling is performed, the riveted copper column or the riveted aluminum column is connected to the high-voltage sampling connector welded on the PCB board.

[0015] In combination with the first aspect, in one embodiment, an injection-molded copper sheet or an injection-molded aluminum sheet is also welded on the overcurrent copper busbar of the wireless bundled BDU, one end of the injection-molded copper sheet or the injection-molded aluminum sheet is welded and fixed to the overcurrent copper busbar, and the other end is welded and fixed to the second nickel sheet welded on the PCB board, so that when voltage sampling is performed, the injection-molded copper sheet or the injection-molded aluminum sheet is connected to the high-voltage sampling connector welded on the PCB board.

[0016] In combination with the first aspect, in one implementation, the PCB board is fixed to the housing by heat riveting.

[0017] In combination with the first aspect, in one embodiment, the novel bolt-free wireless bundled BDU further includes a plurality of third copper bars for connecting to external devices, and ends of the third copper bars for connecting to external devices are in a plug-in style.

[0018] The beneficial effects brought by the technical solution provided in the embodiments of the present application include:

[0019] The entire BDU does not use bolt and nut structures. Relays, safety devices, shunts and other devices are fixed to the copper busbar by welding. The copper busbar and the shell are injection molded together to form a high-voltage overcurrent circuit. Nickel sheets are used for welding, and the low-voltage control and high-voltage sampling circuits are connected through the PCB board. The PCB board is fixed by hot riveting to form low-voltage control and high-voltage sampling circuits. There are no bolts or wireless harnesses in the entire BDU, and the structure is beautiful. The BDU is produced and tested on an automated production line with a simple process flow. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings required for use in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0021] Figure 1 This is a schematic diagram of the structure of the novel wireless bundled BDU without bolt connection in this application;

[0022] Figure 2 It is the structural diagram of the relay;

[0023] Figure 3 A side view of the wireless bundled BDU of this application;

[0024] Figure 4 A top view of the wireless bundled BDU of this application;

[0025] Figure 5 This is a schematic diagram of the structure of the wireless bundled BDU after removing the PCB board for this application;

[0026] In the figure: 1-relay, 2-safety device, 3-locating pin, 4-first positioning hole, 5-first copper bar, 6-first connecting end, 7-second connecting end, 8-locating pin hole, 9-second positioning hole, 10-PCB board, 11-overcurrent copper bar, 12-third copper bar, 13-shunt, 14-fourth positioning hole, 15-second copper bar, 16-fifth positioning hole, 17-sixth positioning hole, 18-first nickel sheet, 19-second nickel sheet. DETAILED DESCRIPTION

[0027] In order to enable those skilled in the art to better understand the solution of the present application, the technical solution in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this application.

[0028] In order to make the objectives, technical solutions and advantages of the present application clearer, the implementation methods of the present application will be further described in detail below with reference to the accompanying drawings.

[0029] The embodiment of the present application provides a new type of wireless bundled BDU without bolt connection. No bolts and nuts are arranged inside the entire BDU. Welding is used to achieve the connection and fixation between various components. There are no bolts or wireless bundles, and the structure is beautiful.

[0030] See also Figure 1 As shown, it is a schematic diagram of the structure of a new type of wireless bundled BDU without bolt connection in the present application. The wireless bundled BDU includes a shell, a relay 1 and a fuse device 2 located in the shell, and a first copper bus 5 located between the relay 1 and the fuse device 2.

[0031] See also Figure 2 As shown, it is a schematic diagram of the structure of the relay 1. A raised positioning pin 3 is provided on the lower end of the relay 1, which is convenient for positioning the end of the first copper bar 5 when the relay 1 is subsequently connected and fixed to the first copper bar 5, so as to ensure the accuracy of the connection between the relay 1 and the first copper bar 5. In order to further improve the accuracy of the connection between the relay 1 and the first copper bar 5, there can be multiple positioning pins 3 provided on the lower end of the relay 1, and the multiple positioning pins 3 are distributed at intervals. Accordingly, a structure matching the position and style of the positioning pin 3 is provided on the end of the first copper bar 5.

[0032] It should be noted that, for the existing relay 1, the contact on the lower end thereof protrudes 6mm from the surface of the relay 1, and the lower end thereof adopts a threaded hole structure, and needs to be connected to the external copper bar by bolt fixing. However, for the relay 1 of the present application, the contact on the lower end thereof protrudes only 1mm from the surface of the relay 1, which effectively reduces the cost, and the overall height of the relay 1 is also reduced, making the relay 1 more miniaturized. At the same time, welding is used to realize the connection between the lower end of the relay 1 and the copper bar.

[0033] At the same time, the control coil of the existing relay 1 adopts an upward copper plug structure, which needs to be connected with a sheathed wire harness, and the control coil protrudes 16.2mm from the surface of the relay 1, and cannot prevent condensation; while for the relay 1 in this application, the control coil adopts a horizontal copper plug structure, which is connected to other components by welding, and the control coil only protrudes 0.8mm from the surface of the relay 1, making the relay 1 more miniaturized as a whole and able to prevent condensation.

[0034] The contact blade of the safety device 2 is provided with a first positioning hole 4. The first copper busbar 5 includes a first connection end 6 and a second connection end 7, the first connection end 6 is provided with a positioning pin hole 8 matched with the positioning pin 3, and the first connection end 6 is welded and fixed to the relay 1, the second connection end 7 is provided with a second positioning hole 9 matched with the first positioning hole 4, and the second connection end 7 is welded and fixed to the safety device 2.

[0035] It should be noted that, for the BDU, there are multiple relays 1 therein, and the multiple relays 1 are arranged in a row. The fuse 2 is located on one side of the relay 1, and one of the relays 1 close to the fuse 2 needs to be connected to the fuse 2 using the first copper bus 5.

[0036] The first copper bar 5 includes two ends, one of which is a first connection end 6, and the other end is a second connection end 7. The first connection end 6 is used to connect and fix with the relay 1. A positioning pin 3 is provided on the lower end of the relay 1, and a positioning pin hole 8 matching the position and shape of the positioning pin 3 is provided on the first connection end 6. Under the cooperation of the positioning pin 3 and the positioning pin hole 8, the first connection end 6 of the first copper bar 5 is positioned on the relay 1. After the relay 1 is installed in the housing, the first connection end 6 of the first copper bar 5 can be welded and fixed to the relay 1 by welding. The welding in this application can be laser welding, ultrasonic welding, resistance welding, etc.

[0037] Furthermore, a third positioning hole is provided on the first connecting end 6 of the first copper busbar 5 for positioning the first connecting end 6 and the relay 1 when they are welded and fixed. The third positioning hole is used to position the first connecting end 6 and the relay 1 when they are welded.

[0038] The second positioning hole 9 on the second connecting end 7 of the first copper bar 5 cooperates with the first positioning hole 4 on the contact knife of the safety device 2 to realize the positioning of the second connecting end 7 of the first copper bar 5 on the contact knife of the safety device 2. At the same time, the second positioning hole 9 can also be used as a positioning hole for welding to weld and fix the safety device 2 and the second connecting end 7 of the first copper bar 5.

[0039] It should be noted that the first copper bar 5 is integrally injection molded with the housing to achieve the positioning of the first copper bar 5. That is, the positioning of the first copper bar 5 is achieved through the positioning of the housing plastic part, ensuring the accuracy of component installation and connection.

[0040] For further information, see Figure 3As shown, the novel bolt-free wireless beam BDU of the present application also includes a shunt 13 located on one side of the relay 1, a fourth positioning hole 14 is provided on the contact blade of the shunt 13, a second copper bar 15 is also provided between the relay 1 and the shunt 13, a fifth positioning hole 16 matching the fourth positioning hole 14 is provided on one end of the second copper bar 15 for connecting the shunt 13, and the second copper bar 15 is welded and fixed to the shunt 13. That is, the connection and positioning between the second copper bar 15 and the shunt 13 are realized by the fifth positioning hole 16 on the second copper bar 15 and the fourth positioning hole 14 on the contact blade of the shunt 13. At the same time, the fifth positioning hole 16 on the second copper bar 15 can also be used for welding positioning when welding between the second copper bar 15 and the shunt 13, so as to accurately weld and fix the second copper bar 15 and the shunt 13. At the same time, the second copper bar 15 is integrally injection-molded with the housing to achieve positioning of the second copper bar 15 , that is, the positioning of the second copper bar 15 is achieved through the plastic part on the housing.

[0041] For further information, see Figure 4 As shown, the novel wireless bundled BDU without bolt connection of the present application also includes a PCB board 10 located at the top of the relay 1, see Figure 5 As shown, a first nickel sheet 18 is provided between the relay 1 and the PCB board 10, one end of the first nickel sheet 18 is welded and fixed to the low-voltage control coil of the relay 1, and the other end is welded and fixed to the PCB board 10, and a sixth positioning hole 17 for positioning the first nickel sheet 18 and the low-voltage control coil during welding is provided on the first nickel sheet 18. The PCB board 10 is fixed to the housing by hot riveting.

[0042] Since the BDU includes multiple relays 1, a first nickel sheet 18 is provided at the top of each relay 1. The low-voltage control coil of the relay 1 is a copper sheet structure. For a single first nickel sheet 18, its lower end is welded and fixed to the low-voltage control coil of the relay 1, and its upper end is welded and fixed to the PCB board 10, and is integrated into the low-voltage control connector through the PCB board 10. A sixth positioning hole 17 is provided on the first nickel sheet 18 to facilitate positioning during welding.

[0043] For the wireless bundled BDU of this application, two welding methods are used for high voltage sampling. In the first welding method, see Figure 4 As shown, a riveted copper column or a riveted aluminum column is also welded on the overcurrent copper bar 11 of the wireless bundled BDU, one end of the riveted copper column or the riveted aluminum column is welded and fixed to the overcurrent copper bar 11, and the other end is welded and fixed to the second nickel sheet 19 welded on the PCB board 10, so that when voltage sampling is performed, the riveted copper column or the riveted aluminum column is connected to the high-voltage sampling connector welded on the PCB board 10; in the first welding method, see Figure 4As shown, an injection-molded copper sheet or an injection-molded aluminum sheet is also welded on the overcurrent copper bus 11 of the wireless bundled BDU, one end of the injection-molded copper sheet or the injection-molded aluminum sheet is welded and fixed to the overcurrent copper bus 11, and the other end is welded and fixed to the second nickel sheet 19 welded on the PCB board 10, so as to be connected to the high-voltage sampling connector welded on the PCB board 10 through the injection-molded copper sheet or the injection-molded aluminum sheet when voltage sampling is performed.

[0044] Furthermore, the new type of wireless bundled BDU without bolt connection of the present application also includes a plurality of third copper bars 12 for connecting to external devices, and the end of the third copper bar 12 for connecting to external devices is a plug-in style. Inside the shell of the wireless bundled BDU of the present application, each device is fixed without bolts and nuts to form a high-voltage overcurrent interruption circuit. The overcurrent copper bar 11 can be made of a copper bar that is first nickel-plated and then tin-plated, or a copper-nickel composite bar, or an aluminum bar, which is treated in the same way.

[0045] Furthermore, all the copper bars in the embodiments of the present application can be in contact with the thermal pad through the water cooling plate through the insulating film to solve the problem of excessive temperature rise when the overcurrent is large.

[0046] The novel wireless bundled BDU without bolt connection in the embodiment of the present application does not use bolt and nut structure inside the entire BDU. The relay 1, the safety device 2, the shunt 13 and other devices are fixed on the copper bus by welding. The copper bus and the shell are injection molded into one to form a high-voltage overcurrent circuit. Nickel sheet welding is used at the same time. The low-voltage control and high-voltage sampling circuits are connected through the PCB board 10. The PCB board 10 is fixed by hot riveting to form low-voltage control and high-voltage sampling circuits. There is no bolt or wireless bundle in the entire BDU, and the structure is beautiful. The BDU is produced and tested on an automated production line, and the process flow is simple.

[0047] In the description of the present application, it should be noted that the terms "upper", "lower", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present application. Unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be an indirect connection through an intermediate medium, or it can be a connection between the two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present application can be understood according to the specific circumstances.

[0048] It should be noted that, in this application, relational terms such as "first" and "second" are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, the elements defined by the sentence "comprise a ..." do not exclude the presence of other identical elements in the process, method, article or device including the elements.

[0049] The above description is only a specific implementation of the present application, so that those skilled in the art can understand or implement the present application. Various modifications to these embodiments will be apparent to those skilled in the art, and the general principles defined herein can be implemented in other embodiments without departing from the spirit or scope of the present application. Therefore, the present application will not be limited to the embodiments shown herein, but will conform to the widest range consistent with the principles and novel features applied for herein.

Claims

1. A novel wireless bundled BDU without bolt connection, characterized in that: The novel bolt-free wireless bundled BDU includes a housing, and located inside the housing: A relay (1), wherein a protruding positioning pin (3) is provided on the lower end of the relay (1); A safety device (2), wherein a first positioning hole (4) is provided on a contact blade of the safety device (2); A first copper bar (5) located between the relay (1) and the safety device (2), the first copper bar (5) comprising a first connection end (6) and a second connection end (7), the first connection end (6) being provided with a positioning pin hole (8) matching with the positioning pin (3), and the first connection end (6) and the relay (1) being fixed by welding, the second connection end (7) being provided with a second positioning hole (9) matching with the first positioning hole (4), and the second connection end (7) and the safety device (2) being fixed by welding; The positioning pin (3) is used to position the end of the first copper bar (5) when the relay (1) is connected and fixed to the first copper bar (5); the second positioning hole (9) on the second connection end (7) of the first copper bar (5) cooperates with the first positioning hole (4) on the contact blade of the safety device (2) to achieve the positioning of the second connection end (7) of the first copper bar (5) on the contact blade of the safety device (2); the second positioning hole (9) is also used as a positioning hole during welding to weld and fix the safety device (2) to the second connection end (7) of the first copper bar (5).

2. A novel wireless bundled BDU without bolt connection as claimed in claim 1, characterized in that: The first connection end (6) is also provided with a third positioning hole for achieving positioning when the first connection end (6) and the relay (1) are welded and fixed, and the second positioning hole (9) cooperates with the first positioning hole (4) to achieve positioning when the second connection end (7) and the safety device (2) are welded and fixed.

3. A novel wireless bundled BDU without bolt connection as claimed in claim 1, characterized in that: The first copper bar (5) is integrally injection-molded with the housing to achieve positioning of the first copper bar (5).

4. A novel wireless bundled BDU without bolt connection as claimed in claim 1, characterized in that: The novel bolt-free wireless bundled BDU also includes a shunt (13) located on one side of the relay (1), a fourth positioning hole (14) is provided on the contact blade of the shunt (13), a second copper bar (15) is provided between the relay (1) and the shunt (13), a fifth positioning hole (16) matching the fourth positioning hole (14) is provided on one end of the second copper bar (15) for connecting to the shunt (13), and the second copper bar (15) and the shunt (13) are fixed by welding.

5. A novel wireless bundled BDU without bolt connection as claimed in claim 4, characterized in that: The second copper bar (15) is integrally injection-molded with the housing to achieve positioning of the second copper bar (15).

6. A novel wireless bundled BDU without bolt connection as claimed in claim 1, characterized in that: The novel bolt-free wireless bundled BDU further comprises a PCB board (10) located at the top of the relay (1), and a first nickel sheet (18) is provided between the relay (1) and the PCB board (10), one end of the first nickel sheet (18) is welded and fixed to the low-voltage control coil of the relay (1), and the other end is welded and fixed to the PCB board (10), and the first nickel sheet (18) is provided with a sixth positioning hole (17) for positioning the first nickel sheet (18) and the low-voltage control coil during welding.

7. A novel wireless bundled BDU without bolt connection as claimed in claim 6, characterized in that: A riveted copper column or a riveted aluminum column is also welded to the overcurrent copper busbar (11) of the wireless bundled BDU, one end of the riveted copper column or the riveted aluminum column is welded and fixed to the overcurrent copper busbar (11), and the other end is welded and fixed to a second nickel sheet (19) welded on the PCB board (10), so that when voltage sampling is performed, the riveted copper column or the riveted aluminum column is connected to a high-voltage sampling connector welded on the PCB board (10).

8. A novel wireless bundled BDU without bolt connection as claimed in claim 6, characterized in that: An injection-molded copper sheet or an injection-molded aluminum sheet is also welded to the overcurrent copper bar (11) of the wireless bundled BDU. One end of the injection-molded copper sheet or the injection-molded aluminum sheet is welded and fixed to the overcurrent copper bar (11), and the other end is welded and fixed to a second nickel sheet (19) welded on the PCB board (10), so that when voltage sampling is performed, the injection-molded copper sheet or the injection-molded aluminum sheet is connected to a high-voltage sampling connector welded on the PCB board (10) through the injection-molded copper sheet or the injection-molded aluminum sheet.

9. A novel wireless bundled BDU without bolt connection as claimed in any one of claims 6 to 8, characterized in that: The PCB board (10) is fixed on the housing by heat riveting.

10. A novel wireless bundled BDU without bolt connection as claimed in claim 1, characterized in that: The novel bolt-free wireless bundled BDU further comprises a plurality of third copper bars (12) for connecting to external devices, and the ends of the third copper bars (12) for connecting to external devices are in the form of plug-in pieces.

Images