Assembly method and assembly structure of power distribution unit and quick-change connector

Abstract

The invention discloses an assembling method and an assembling structure of a power distribution unit and a quick-change connector. The assembling method comprises the following steps: step 1, a positive terminal and a negative terminal of the power distribution unit are respectively pre-connected to the bottom of a power distribution unit shell, and connecting holes are respectively formed in the positive terminal and the negative terminal; step 2, a quick-change connector is fixed below the bottom of the power distribution unit shell, and an interval space is reserved between the top of the quick-change connector and the bottom of the power distribution unit shell; 3, enabling a screw to penetrate through the bottom of the power distribution unit shell and the connecting hole of the positive terminal or the negative terminal, and inserting the screw into the inlet of the positive terminal hole or the negative terminal hole of the quick-change connector; and step 4, screwing the screw until the screw fixes the positive terminal or the negative terminal of the power distribution unit and the quick-change connector together. According to the technical scheme, the quick-change connector can be quickly and accurately connected to the bottom of the power distribution unit.

Description

Technical Field

[0001] The present invention relates to the technical field of new energy electric vehicles, and in particular to an assembly method and an assembly structure of a power distribution unit and a quick-change connector. Background Art

[0002] The three small electrics usually refer to the three key power electronic components in new energy vehicles, which are responsible for power conversion and power management. Specifically, the three small electrics include: On-board charger (OBC): converts external input AC power into DC power to charge the power battery of the electric vehicle; DC / DC converter: converts a certain DC power supply voltage into any DC voltage to provide the required power for the power steering system, air conditioning and other auxiliary equipment; Power distribution unit (PDU, also known as high-voltage distribution box): including relays, insurance and other components, responsible for managing and distributing high voltage electricity, and providing power for the vehicle's high-voltage system. The above components play a vital role in new energy vehicles. Together, they ensure that the vehicle can operate efficiently and safely. Among them, the power distribution unit is generally connected to the car battery through a quick-change connector. Due to space limitations, how to reasonably layout the quick-change connector is a common problem.

[0003] At present, quick-change connectors are generally designed on the side of the power distribution unit to avoid the problem of the positive and negative mounting points of the quick-change connector being blocked when it is installed at the bottom of the bottom power distribution unit. However, this arrangement will cause the space at the top of the quick-change connector to be unutilized, the power density of the whole machine is low, and the space utilization rate is insufficient. On the other hand, if the quick-change connector is arranged at the bottom of the power distribution unit, the positive and negative plugs of the quick-change connector float in the three directions of the XYZ axis, making it difficult to align the electrode terminal holes on it, increasing the difficulty of assembly. Summary of the invention

[0004] An embodiment of the present invention provides an assembly method and assembly structure of a power distribution unit and a quick-change connector to solve the problems that the arrangement structure of the existing power distribution unit and the quick-change connector is unreasonable and that if they are to be arranged at the bottom, the line of sight is blocked by the power distribution unit and cannot be installed normally.

[0005] According to an embodiment of one aspect of the present invention, a method for assembling a power distribution unit and a quick-change connector includes:

[0006] Step 1: pre-connect the positive terminal and the negative terminal of the power distribution unit to the bottom of the power distribution unit housing, respectively, wherein the positive terminal and the negative terminal are respectively provided with connection holes;

[0007] Step 2: arrange the quick-change connector below the bottom of the power distribution unit housing, and reserve a spacing space between the top of the quick-change connector and the bottom of the power distribution unit housing;

[0008] Step 3: insert the screw through the bottom of the power distribution unit housing, the connection hole of the positive terminal or the negative terminal, and into the entrance of the positive terminal hole or the negative terminal hole of the quick-change connector;

[0009] Step 4: Tighten the screw until the screw fixes the positive terminal or the negative terminal of the power distribution unit and the quick-change connector together.

[0010] In some embodiments, the positive terminal and the negative terminal of the power distribution unit are flexible terminals, and the flexible terminals are any one of the following: a soft copper bus, a braided belt, or a wire harness.

[0011] In some embodiments, a screw installation hole is provided at the bottom of the power distribution unit housing, and the pre-connection is a snap connection or an adhesive connection, and step one further comprises:

[0012] During the pre-connection, the connection holes of the positive terminal and the negative terminal are aligned or approximately aligned with the screw installation holes.

[0013] In some embodiments, in step 2, the vertical distance between the upper end surface of the positive terminal hole or the negative terminal hole of the quick-change connector and the contact surface between the bottom of the power distribution unit shell and the positive terminal or the negative terminal is greater than the thread length of the screw and less than the sum of the thread length of the screw and the guide end length of the screw.

[0014] In some embodiments, in step three, after the screw passes through the connection hole of the positive terminal or the negative terminal of the power distribution unit, the guide end of the screw enters the positive terminal hole or the negative terminal hole of the quick-change connector accordingly.

[0015] In some embodiments, in step four, the positive terminal or negative terminal pre-connected on the bottom of the power distribution unit shell is detached from the power distribution unit shell by the axial force generated by screwing the screw, and as the torque of screwing the screw increases, the positive terminal or negative terminal of the power distribution unit is connected to the positive terminal hole or negative terminal hole of the quick-change connector.

[0016] In some embodiments, in step one, the pre-tightening force generated during pre-connection needs to be greater than the self-gravity of the positive terminal or the negative terminal and the vibration force generated during installation or transportation, and less than the force generated when screwing the screw, thereby ensuring that the positive terminal and the negative terminal do not fall off before installation and can fall off normally during installation.

[0017] According to another aspect of the present invention, an assembly structure of a power distribution unit and a quick-change connector is provided. In some embodiments, the assembly structure includes:

[0018] A power distribution unit, the power distribution unit comprising a positive terminal and a negative terminal, the positive terminal and the negative terminal are respectively provided with connection holes, and a screw mounting hole is provided at the bottom of the power distribution unit housing, the screw mounting hole can allow a screw to pass through;

[0019] The quick-change connector is arranged at the bottom of the power distribution unit shell. The screw is passed through the installation hole of the power distribution unit, the connection hole of the positive terminal or the negative terminal, and then screwed into the positive terminal hole or the negative terminal hole of the quick-change connector to achieve the connection between the quick-change connector and the power distribution unit.

[0020] In some embodiments, a pre-connection structure is further included, wherein the pre-connection structure pre-connects the positive terminal and the negative terminal to the bottom of the power distribution unit housing, and aligns or substantially aligns the screw installation hole with the connection hole;

[0021] The pre-connection structure is configured as follows: the pre-tightening force generated during pre-connection must be greater than the self-gravity of the positive terminal or the negative terminal and the vibration force generated during installation or transportation, and less than the force generated when screwing the screw, thereby ensuring that the positive terminal and the negative terminal do not fall off before installation and can fall off normally during installation.

[0022] In some embodiments, the pre-connection structure is a snap-fit ​​structure or an adhesive structure; and / or,

[0023] The components arranged above the mounting holes are detachable components; and / or,

[0024] The ferrule in the quick-change connector can float in three directions, XYZ, and the ferrule is provided with a positive terminal hole and a negative terminal hole; and / or,

[0025] The positive terminal and the negative terminal are flexible terminals.

[0026] Compared with the prior art, the embodiments of the present invention have the following advantages:

[0027] The embodiments of the present invention mainly solve the problem that the quick-change connector cannot be installed normally because the positive and negative terminal holes of the quick-change connector are blocked by the power distribution unit because the quick-change connector is located at the bottom of the power distribution unit. By designing the assembly scheme in the embodiments of the present invention, it is possible to achieve fast and accurate installation of the power distribution unit and the quick-change connector without obstructing the line of sight. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 It is a flowchart of an assembly method of a power distribution unit and a quick-change connector provided by some embodiments of the present invention;

[0029] Figure 2 It is a structural schematic diagram of the assembly position of the power distribution unit and the quick-change connector provided in some embodiments of the present invention;

[0030] Figure 3 is a schematic diagram of the structure of a power distribution unit provided by some embodiments of the present invention without easily detachable parts;

[0031] Figure 4 It is a schematic diagram of a structure in which the positive and negative terminals of a power distribution unit provided by some embodiments of the present invention are pre-connected to a housing;

[0032] Figure 5 yes Figure 4 An enlarged view of the pre-connection positions of the positive and negative terminals of the power distribution unit;

[0033] Figure 6 is a schematic diagram of the structure of a power distribution unit and a quick-change connector in an initial state before the screws are tightened, provided in some embodiments of the present invention;

[0034] Figure 7 yes Figure 6 A partial enlarged view of

[0035] Figure 8 It is a schematic diagram of the structure after the positive and negative terminals of the power distribution unit and the positive and negative terminal holes of the quick-change connector are assembled.

[0036] Notes on the attached drawings:

[0037] 1. Power distribution unit, 11. Removable parts, 12. Positive or negative terminal, 13. Snap-on structure, 131. First snap-on structure, 132. Second snap-on structure, 14. Power distribution unit housing; 2. Screws; 3. Quick-change connector, 31. Positive or negative terminal hole, 32. Quick-change connector housing, 33. Insert. DETAILED DESCRIPTION

[0038] Many specific details are set forth in the following description to facilitate a full understanding of the present invention. However, the present invention can be implemented in many other ways than those described herein, and those skilled in the art can make similar generalizations without violating the connotation of the present invention, so the present invention is not limited to the specific implementation disclosed below.

[0039] In the description of the present invention, it should be understood that descriptions involving orientations, such as up, down, front, back, left, right, etc., and orientations or positional relationships indicated are based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present invention.

[0040] In the description of the present invention, unless otherwise clearly defined, terms such as setting, installing, connecting, etc. should be understood in a broad sense, and technicians in the relevant technical field can reasonably determine the specific meanings of the above terms in the present invention based on the specific content of the technical solution.

[0041] In the description of the present invention, the description with reference to terms such as "one embodiment", "some embodiments", "illustrative embodiment", "example", "specific example", or "some examples" means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention.

[0042] See also Figure 1-7 As shown, an embodiment of the present invention discloses a method for assembling a power distribution unit and a quick-change connector, comprising:

[0043] Step 1: pre-connect the positive terminal and the negative terminal 12 of the power distribution unit 1 to the bottom of the power distribution unit housing 14, respectively, wherein the positive terminal and the negative terminal 12 are respectively provided with connection holes, the diameter of the connection holes is slightly larger than the diameter of the screw in the screw 2 to be assembled, or the connection holes are threaded holes matching the threads of the screws;

[0044] Step 2: Set the quick-change connector 3 below the bottom of the power distribution unit housing 14. Figure 2 and Figure 3 As shown, a spacing space is reserved between the top of the quick-change connector 3 and the bottom of the power distribution unit housing 14; optionally, before assembling this embodiment, the quick-change connector 3 and the power distribution unit 1 are pre-fixed and connected to the same housing structure;

[0045] It should be noted that the order of step 1 and step 2 is not fixed, and step 1 can be performed first or step 2 can be performed first.

[0046] Step three, insert the screw 2 through the bottom of the power distribution unit housing 14, the connection hole of the positive terminal or the negative terminal 12, and into the entrance of the positive terminal hole or the negative terminal hole 31 of the quick-change connector 3; optionally, the positive terminal hole and the negative terminal hole 31 are set on the same plug core 33;

[0047] Step 4: screw the screw 2 until the screw 2 fixes the positive terminal or negative terminal 12 of the power distribution unit 1 and the quick-change connector 3 together.

[0048] The above-mentioned embodiment of the present invention, by designing a pre-connection structure, enables the positive and negative terminals to be fixed in advance, so that the screws can be passed through and accurately inserted into the positive and negative terminal holes of the quick-change connector.

[0049] In some embodiments, in order to facilitate the adjustment of the orientation of the screw 2 when inserted into the plug 33, the positive terminal and the negative terminal 12 of the power distribution unit 1 are flexible terminals, and the flexible terminals are any one of the following: soft copper busbars, conductive braided belts or conductive wire harnesses.

[0050] In some embodiments, a screw mounting hole is provided at the bottom of the power distribution unit housing 14, through which the entire screw including the nut can pass, so that the screw can pass through the housing and enter the spacing space between the power distribution unit 1 and the quick-change connector 3.

[0051] The pre-connection is a snap connection or an adhesive connection. The pre-connection is achieved by snap connection, adhesive connection and other detachable connection methods that can achieve a smaller connection force, and no specific limitation is made here.

[0052] Specific, combined Figure 4 and Figure 5 As shown, the snap connection specifically includes two snap structures 13. The first snap structure 131 includes snap holes provided on the positive and negative terminals, and a raised snap portion provided on the bottom of the power distribution unit housing. The snap portion is installed in the snap holes on the positive and negative terminals during pre-connection. The other structure is shown in FIG. Figure 5 As shown, a second snap-fit ​​structure 132 is provided at the contact position between the side walls of the positive and negative terminals and the bottom of the power distribution unit shell, so that the positive and negative terminals are snapped into the recessed space at the bottom of the power distribution unit shell by the second snap-fit ​​structure 132 .

[0053] but Figure 1 Step 1 in the method further includes: during pre-connection, aligning or approximately aligning the connection holes of the positive terminal and the negative terminal with the screw installation holes, so as to facilitate the insertion and position adjustment of the screws.

[0054] In some embodiments, in step 2, combining Figure 6 and Figure 7As shown, the vertical distance L between the upper end surface of the positive terminal hole or the negative terminal hole 31 of the quick-change connector 3 and the contact surface between the bottom of the power distribution unit shell 14 and the positive terminal or the negative terminal is greater than the thread length L1 of the screw, and less than the sum of the thread length L1 of the screw and the guide end length L2 of the screw.

[0055] It should be noted that before assembly, the easily removable part 11 covering the screw installation hole position needs to be removed to expose the screw installation hole position for easy assembly operation. Optionally, the easily removable part is a device such as a fuse.

[0056] In some embodiments, in step three, according to Figure 7 As shown, after the screw 2 passes through the connection hole of the positive terminal or the negative terminal of the power distribution unit 1, the guide end of the screw enters the positive terminal hole or the negative terminal hole 31 of the quick-change connector accordingly.

[0057] In some embodiments, in step 4, the positive terminal or negative terminal pre-connected to the bottom of the power distribution unit housing 14 is detached from the power distribution unit housing 14 by the axial force generated by screwing the screw 2, and as the torque of screwing the screw 2 is increased, the positive terminal or negative terminal of the power distribution unit 1 is connected to the positive terminal hole or negative terminal hole 31 of the quick-change connector 3. The final connection structure is shown in FIG. Figure 8 shown.

[0058] In some embodiments, in step one, the pre-tightening force generated during pre-connection needs to be greater than the self-gravity of the positive terminal or the negative terminal 12 and the vibration force generated during installation or transportation, and less than the force generated when screwing the screw 2, thereby ensuring that the positive terminal and the negative terminal 12 do not fall off before installation and can fall off normally during installation.

[0059] According to another aspect of the present invention, an assembly structure of a power distribution unit and a quick-change connector is provided, Figure 2-Figure 8 As shown, the assembly structure includes:

[0060] A power distribution unit 1, the power distribution unit 1 includes a positive terminal and a negative terminal 12, the positive terminal and the negative terminal 12 are respectively provided with connection holes, and a screw mounting hole is provided at the bottom of the power distribution unit shell, and the screw mounting hole can allow a screw 2 to pass through; wherein, the diameter of the connection hole respectively provided on the positive terminal and the negative terminal 12 is slightly larger than the diameter of the screw in the screw 2 to be assembled, or the connection hole is a threaded hole that matches the thread of the screw.

[0061] The quick-change connector 3 is arranged at the bottom of the power distribution unit shell 14. The screw 2 passes through the screw installation hole of the power distribution unit 1 and the connection hole of the positive terminal or the negative terminal and is screwed into the positive terminal hole or the negative terminal hole 31 of the quick-change connector 3 to realize the connection between the quick-change connector 3 and the power distribution unit 1.

[0062] Combination Figure 7 As shown, when fixing the quick-change connector, it is necessary to set the vertical distance L between the upper end surface of the positive terminal hole or the negative terminal hole 31 of the quick-change connector 3 and the contact surface between the bottom of the power distribution unit shell 14 and the positive terminal or the negative terminal to be greater than the thread length L1 of the screw, and less than the sum of the thread length L1 of the screw and the guide end length L2 of the screw.

[0063] In some embodiments, a pre-connection structure is also included, which pre-connects the positive terminal and the negative terminal to the bottom of the power distribution unit housing 14 and aligns or approximately aligns the mounting hole and the connection hole.

[0064] The pre-connection structure is configured as follows: the pre-tightening force generated during pre-connection must be greater than the self-gravity of the positive terminal or the negative terminal 12 and the vibration force generated during installation or transportation, and less than the force generated when screwing the screw 2, thereby ensuring that the positive terminal and the negative terminal do not fall off before installation and can fall off normally during installation.

[0065] In some embodiments, the pre-connection structure is a snap-fit ​​structure 13 or an adhesive structure; the snap-fit ​​structure includes Figure 4 and Figure 5 The first buckle structure 131 and the second buckle structure 132 are shown in FIG.

[0066] Specific, combined Figure 4 and Figure 5 As shown, the snap connection specifically includes two snap structures 13. The first snap structure 131 includes snap holes provided on the positive and negative terminals, and a raised snap portion provided on the bottom of the power distribution unit housing. The snap portion is installed in the snap holes on the positive and negative terminals during pre-connection. The other structure is shown in FIG. Figure 5 As shown, a second snap-fit ​​structure 132 is provided at the contact position between the side walls of the positive and negative terminals and the bottom of the power distribution unit shell, so that the positive and negative terminals are snapped into the recessed space at the bottom of the power distribution unit shell by the second snap-fit ​​structure 132 .

[0067] The components arranged above the screw installation holes 31 are detachable components; optionally, the components are easily detachable parts 11, and the easily detachable parts 11 may be fuses or the like.

[0068] The insert 33 in the quick-change connector 3 can float in three directions, X, Y, and Z. The insert 33 is disposed in the connector housing 32 , and a positive terminal hole and a negative terminal hole 31 are disposed on the insert 33 .

[0069] The positive terminal and the negative terminal 12 are flexible terminals. Optionally, the flexible terminals may be structures such as soft copper bars, conductive braided belts or conductive wire harnesses.

[0070] In summary, the embodiments of the present invention can achieve the following beneficial effects:

[0071] The above-mentioned embodiment of the present invention provides an assembly scheme for a power distribution unit and a quick-change connector. When the quick-change connector is arranged above and below the power distribution unit, the positive and negative terminals of the power distribution unit and the plug in the quick-change connector cannot be normally assembled because the plug where the electrode terminals are located in the quick-change connector has corresponding floating space in the three directions of XYZ. In the embodiment of the present invention, the positive and negative terminals connected between the power distribution unit and the quick-change connector adopt flexible structures such as soft copper busbars, braided belts or wiring harnesses, and the power distribution unit and its own positive and negative poles are fixed to the power distribution unit housing by snaps or other pre-fixing methods, and then the distance between the power distribution unit and the quick-change connector is controlled to ensure that the guide end of the screw can be located at the end of the quick-change positive and negative terminal holes. The positive and negative terminals of the power distribution unit are separated from the pre-fixing points of the power distribution unit by the axial force of the screw. As the torque of the screw increases, the quick-change connector and the positive and negative terminals of the power distribution unit are quickly and accurately connected.

[0072] It should be noted that although the present invention is disclosed as above in the form of a preferred embodiment, it is not intended to limit the present invention. Any technical personnel in this field may make possible changes and modifications without departing from the spirit and scope of the present invention. Therefore, the scope of protection of the present invention shall be based on the scope defined by the claims of the present invention.

Claims

1. A method for assembling a power distribution unit and a quick-change connector, characterized in that: include: Step 1: pre-connect the positive terminal and the negative terminal of the power distribution unit to the bottom of the power distribution unit housing, respectively, wherein the positive terminal and the negative terminal are respectively provided with connection holes; Step 2: arrange the quick-change connector below the bottom of the power distribution unit housing, and reserve a spacing space between the top of the quick-change connector and the bottom of the power distribution unit housing; Step 3: insert the screw through the bottom of the power distribution unit housing, the connection hole of the positive terminal or the negative terminal, and into the entrance of the positive terminal hole or the negative terminal hole of the quick-change connector; Step 4: Tighten the screw until the screw fixes the positive terminal or the negative terminal of the power distribution unit and the quick-change connector together.

2. The method for assembling a power distribution unit and a quick-change connector according to claim 1, characterized in that: The positive terminal and the negative terminal of the power distribution unit are flexible terminals, and the flexible terminals are any one of the following: a soft copper bus, a braided belt or a wire harness.

3. The method for assembling a power distribution unit and a quick-change connector according to claim 1, characterized in that: The bottom of the power distribution unit housing is provided with screw mounting holes, the pre-connection is a snap connection or an adhesive connection, and step one further comprises: During the pre-connection, the connection holes of the positive terminal and the negative terminal are aligned or approximately aligned with the screw installation holes.

4. The method for assembling a power distribution unit and a quick-change connector according to claim 1, characterized in that: In step two, the vertical distance between the upper end surface of the positive terminal hole or the negative terminal hole of the quick-change connector and the contact surface between the bottom of the power distribution unit shell and the positive terminal or the negative terminal is greater than the thread length of the screw and less than the sum of the thread length of the screw and the guide end length of the screw.

5. The method for assembling a power distribution unit and a quick-change connector according to any one of claims 1 to 4, characterized in that: In step three, after the screw passes through the connection hole of the positive terminal or the negative terminal of the power distribution unit, the guide end of the screw enters the positive terminal hole or the negative terminal hole of the quick-change connector accordingly.

6. The method for assembling a power distribution unit and a quick-change connector according to any one of claims 1 to 4, characterized in that: In step four, the axial force generated by screwing the screw causes the positive terminal or negative terminal pre-connected on the bottom of the power distribution unit shell to be detached from the power distribution unit shell, and as the torque of screwing the screw increases, the positive terminal or negative terminal of the power distribution unit is connected to the positive terminal hole or negative terminal hole of the quick-change connector.

7. The method for assembling a power distribution unit and a quick-change connector according to claim 6, characterized in that: In step one, the pre-tightening force generated during pre-connection must be greater than the self-gravity of the positive terminal or the negative terminal and the vibration force generated during installation or transportation, and less than the force generated when screwing the screw, thereby ensuring that the positive terminal and the negative terminal do not fall off before installation and can fall off normally during installation.

8. An assembly structure of a power distribution unit and a quick-change connector, characterized in that: The assembly structure comprises: A power distribution unit, the power distribution unit comprising a positive terminal and a negative terminal, the positive terminal and the negative terminal are respectively provided with connection holes, and a screw mounting hole is provided at the bottom of the power distribution unit housing, the screw mounting hole can allow a screw to pass through; The quick-change connector is arranged at the bottom of the power distribution unit shell. The screws are passed through the screw mounting holes of the power distribution unit, the connection holes of the positive terminal or the negative terminal, and then screwed into the positive terminal hole or the negative terminal hole of the quick-change connector to achieve the connection between the quick-change connector and the power distribution unit.

9. The assembly structure of the power distribution unit and the quick-change connector according to claim 8, characterized in that: It also includes a pre-connection structure, which pre-connects the positive terminal and the negative terminal to the bottom of the power distribution unit housing, and aligns or approximately aligns the screw installation hole with the connection hole; The pre-connection structure is configured as follows: the pre-tightening force generated during pre-connection must be greater than the self-gravity of the positive terminal or the negative terminal and the vibration force generated during installation or transportation, and less than the force generated when screwing the screw, thereby ensuring that the positive terminal and the negative terminal do not fall off before installation and can fall off normally during installation.

10. The assembly structure of the power distribution unit and the quick-change connector according to claim 9, characterized in that: The pre-connection structure is a snap-fit ​​structure or an adhesive structure; and / or, The components arranged above the mounting holes are detachable components; and / or, The ferrule in the quick-change connector can float in three directions, XYZ, and the ferrule is provided with a positive terminal hole and a negative terminal hole; and / or, The positive terminal and the negative terminal are flexible terminals.

Images