Vehicle-mounted power supply system and control method

Abstract

The invention provides a vehicle-mounted power supply system and a control method. The system comprises a battery management controller, a battery current collection box, a vehicle-mounted charger, a direct-current converter and a power distribution unit which are integrated in a high-voltage power supply box, the battery management controller, the vehicle-mounted charger and the direct-current converter share a control module, and the vehicle-mounted charger and the direct-current converter share a main circuit; if the control module receives the charging request, a first loop for communicating the power battery with the vehicle-mounted charger is formed through the main circuit, and the power battery is charged; if the voltage conversion request is received, forming a second loop for communicating the power battery and the direct current converter through the main circuit, and performing voltage conversion on the input or output voltage; the control module monitors the state data of the power battery in real time and manages the power battery according to the state data, the power distribution unit is used for the power distribution function of a plurality of high-voltage electric appliances, and according to the vehicle-mounted power supply system, the cost, the size and the volume of the vehicle-mounted power supply system are reduced, and the weight is also reduced.

Description

Technical Field

[0001] The present application relates to the field of vehicle electronic control technology, and in particular to a vehicle-mounted power supply system and a control method. Background Art

[0002] In electric vehicles, the on-board power network is a key system of the vehicle, which is used to realize the conversion, transmission and distribution of high-voltage electricity. Among them, low cost and miniaturization are the current development trends of electric vehicle power technology.

[0003] However, in the related art, as core components in the vehicle power supply, for example, BMC (battery management controller) and BJB (battery junction box) are mechanically integrated inside the battery, and OBC (on-board charger), DC / DC (direct current converter), and PDU (power distribution unit) exist as separate components, or are integrated into one piece in pairs. Due to the low integration of the vehicle power supply, the electronic control is not only large in size but also overweight (heavy), and cannot be miniaturized. In this way, the manufacturing cost of the vehicle is also increased due to the repeated use of the same electronic components. Summary of the invention

[0004] In view of the above-mentioned shortcomings of the prior art, the purpose of the present application is to provide a vehicle-mounted power supply system and a control method, so as to solve the problems of high cost and large size of the prior art vehicle-mounted power supply system.

[0005] To achieve the above-mentioned purpose and other related purposes, the first aspect of the present application provides a vehicle-mounted power supply system, including a power battery, a high-voltage power supply box electrically connected to the power battery, and a battery management controller, a battery collector box, an on-board charger, a DC converter and a power distribution unit integrated in the high-voltage power supply box; the battery management controller, the on-board charger and the DC converter share a control module, and the on-board charger and the DC converter share a main circuit; if the control module receives a charging request, it forms a first circuit connecting the power battery and the on-board charger through the main circuit to charge the power battery; if it receives a voltage conversion request, it forms a second circuit connecting the power battery and the DC converter through the main circuit to convert the input or output DC voltage; the control module monitors the status data of the power battery in real time, and manages the power battery according to the status data, so that the power distribution unit completes the power distribution function.

[0006] In certain embodiments of the first aspect of the present application, the control module includes a multi-core microcontroller having multiple processing cores, and the multi-core microcontroller is configured to respond to a task request by calling a processing core that matches the task request type to respond, and the task request types generated by the battery management controller, the on-board charger and the DC converter are different.

[0007] In certain embodiments of the first aspect of the present application, the multi-core microcontroller configures the priority level of each processing core according to the processing performance of each processing core, and responds according to the priority of the type of the received task request that matches the processing core of the corresponding priority level; wherein the priority of the task request type corresponds one-to-one to the priority of the processing core; if any of the task requests matches one of the processing cores, the processing core is called to respond; if any of the task requests matches multiple processing cores at the same time, the processing core with the least number of task request queues is selected to respond; if any of the task requests matches only one of the processing cores, and the number of task request queues currently mounted on the processing core exceeds a preset threshold, the processing core with a priority higher than the priority corresponding to the current task request is selected to respond.

[0008] In certain embodiments of the first aspect of the present application, the DC converter includes a bidirectional DCDC, and the battery collector box pre-charges or actively discharges the power battery through the bidirectional DCDC.

[0009] In certain embodiments of the first aspect of the present application, the DC converter further includes a first switch, a second switch and a support capacitor, the positive electrode of the power battery is connected to the first end of the bidirectional DCDC through the first switch, the negative electrode of the power battery is connected to the second end of the bidirectional DCDC through the second switch, and the support capacitor is arranged outside the vehicle power system and connected in parallel between the first end and the second end.

[0010] In certain embodiments of the first aspect of the present application, the battery management controller, the battery collector box, the on-board charger, the DC converter and the power distribution unit share a cooling system, and the cooling system includes at least one of air cooling, water cooling, oil cooling, air cooling and phase change cooling.

[0011] In certain embodiments of the first aspect of the present application, the high-voltage power supply box is integrated into the battery pack where the power battery is located, or the high-voltage power supply box is covered on top of the battery pack through an installation interface.

[0012] In certain embodiments of the first aspect of the present application, if the high-voltage power supply box is integrated into the battery pack where the power battery is located, the power battery shares a cooling system with the battery management controller, the battery collector box, the on-board charger, the DC converter, and the power distribution unit.

[0013] In certain embodiments of the first aspect of the present application, the battery management controller, the battery collector box, the on-board charger, the DC converter and the power distribution unit are integrated in the high-voltage power supply box via a signal socket or a high-voltage busbar.

[0014] In certain embodiments of the first aspect of the present application, the main circuit is an integrated vehicle charger, including a multiplexing device required for the operation of the DC converter, and the multiplexing device includes a high-voltage filter component, a transformer component, a power switch tube, a drive component and a discharge component.

[0015] The second aspect of the present application provides a control method for a vehicle-mounted power supply system, comprising a power battery, a high-voltage power supply box electrically connected to the power battery, and a battery management controller, a battery collector box, an on-board charger, a DC converter and a power distribution unit integrated in the high-voltage power supply box; the battery management controller, the on-board charger and the DC converter share a control module, and the on-board charger and the DC converter share a main circuit; wherein the control method comprises: using the control module to monitor the status data of the power battery in real time, and managing the power battery according to the status data so that the power distribution unit completes the power distribution of the external high-voltage load; if a charging request is received, a first circuit connecting the power battery and the on-board charger is formed through the main circuit to charge the power battery; if a voltage conversion request is received, a second circuit connecting the power battery and the DC converter is formed through the main circuit to convert the input or output DC voltage.

[0016] As described above, a technical solution of the vehicle power system and control method described in this application has the following beneficial effects:

[0017] The present application integrates a battery management controller, a battery collector box, an on-board charger, a DC converter and a power distribution unit into a high-voltage power supply box, and at the same time, the battery management controller, the on-board charger and the DC converter share a control module, and the on-board charger and the DC converter share a main circuit. On the one hand, by reusing the same components, the number of the same components used is greatly reduced without affecting the original performance; on the other hand, by improving the integration of the on-board power supply system, not only the cost of the on-board power supply system is reduced, the size and volume of the on-board power supply system are reduced, and at the same time, the weight of the on-board power supply system is reduced, and the working efficiency of the on-board power supply system is also improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 Shown is an implementation environment diagram of a vehicle power system provided by the present application;

[0019] Figure 2 Shown is a structural block diagram of a vehicle power system provided by this application;

[0020] Figure 3 Shown is a schematic diagram of the layout of a medium and high voltage power supply box in an electric vehicle provided by the present application;

[0021] Figure 4 Shown is a new and old comparison diagram of a vehicle power system provided by this application;

[0022] Figure 5 Shown is a comparison diagram of a new and old pre-charge and discharge circuit solution provided by the present application;

[0023] Figure 6 Shown is a cooling schematic diagram of a vehicle-mounted power system provided by the present application;

[0024] Figure 7 Shown is a flow chart of a control method based on a vehicle power system provided by the present application. DETAILED DESCRIPTION

[0025] The following describes the embodiments of the present application through specific examples, and those skilled in the art can easily understand other advantages and effects of the present application from the contents disclosed in this specification. The present application can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed in various ways based on different viewpoints and applications without departing from the spirit of the present application. It should be noted that the following embodiments and features in the embodiments can be combined with each other without conflict.

[0026] It should be noted that the illustrations provided in the following embodiments are only schematic illustrations of the basic concept of the present application, and thus the drawings only show components related to the present application rather than being drawn according to the number, shape and size of components in actual implementation. In actual implementation, the type, quantity and proportion of each component may be changed at will, and the component layout may also be more complicated.

[0027] As mentioned in the background technology above, the inventors have found that with the promotion and application of electric vehicles, thanks to the cost reduction advantages and structural miniaturization advantages brought by the deep integration of all-in-one products, the gradual entry of all-in-one on-board power systems into the market has become a future technological trend.

[0028] However, the current integration of all-in-one products in vehicle power systems is mainly based on mechanical integration. Only some products have weak current control integration, and almost no products involve deep power topology integration. Mechanical integration has almost reached its limit. Weak current control integration can only reduce circuit boards, and has little contribution to cost reduction, efficiency improvement and structural miniaturization design. At the same time, complex vehicle power systems such as vehicle chargers and battery management controllers require multiple large-sized and large-volume power switch tubes to form a bridge power circuit, and the overall size of the corresponding vehicle power system is still relatively large. This makes it impossible to further improve the integration of all-in-one vehicle power systems, which will limit related applications.

[0029] Based on this, the present invention proposes an all-in-one vehicle power system technical solution: please refer to Figure 1 , taking the on-board power supply system executed by a target vehicle as an example, the target vehicle includes a power battery, a high-voltage power supply box electrically connected to the power battery, and a battery management controller, a battery collector box, an on-board charger, a DC converter and a power distribution unit integrated in the high-voltage power supply box; the battery management controller, the on-board charger and the DC converter share a control module, and the on-board charger and the DC converter share a main circuit; if the control module receives a charging request, a first circuit connecting the power battery and the on-board charger is formed through the main circuit to charge the power battery; if a voltage conversion request is received, a second circuit connecting the power battery and the DC converter is formed through the main circuit to convert the input or output DC voltage; the control module monitors the status data of the power battery in real time, and manages the power battery according to the status data, so that the power distribution unit completes the power distribution of the external high-voltage load.

[0030] Through the above method, the main circuit is reused as the on-board charger and the DC converter to refine the primary circuit of the DC conversion unit. By reusing high-voltage filter components, transformer components, power switch tubes and drivers, passive discharge components, etc., the power circuit topology of the all-in-one electric drive power system is streamlined, the integration of the all-in-one on-board power system is improved, and the working efficiency of the on-board charger module is improved; the control circuit of the battery management controller, the control circuit of the on-board charger and the control circuit of the DC converter are integrated on a circuit board to reduce the number of required circuit boards.

[0031] The present invention is described in detail below through specific embodiments. Figure 2 As shown, Figure 2 A structural block diagram of a vehicle power system provided for this application is described as follows:

[0032] A power battery, a high-voltage power supply box directly connected to the power battery through a high-voltage busbar, and a battery management controller 21, an on-board charger 22, a DC converter 23 and a power distribution unit 24 integrated in the high-voltage power supply box 2;

[0033] The battery management controller 21, the on-board charger 22 and the DC converter 23 share a control module 26 (i.e., one control module), and the on-board charger 22 and the DC converter 23 share a main circuit 27 (i.e., one main circuit); if the control module 26 receives a charging request, it forms a first circuit connecting the power battery and the on-board charger through the main circuit to charge the power battery; if it receives a voltage conversion request, it forms a second circuit connecting the power battery and the DC converter through the main circuit to perform voltage conversion on the input or output DC voltage;

[0034] The control module 26 monitors the status data of the power battery in real time and manages the power battery according to the status data; the power distribution unit adjusts the power distribution strategy based on the status data.

[0035] It should be understood that the battery management controller 21 is responsible for real-time monitoring of the status data of the power battery, including but not limited to the voltage, current, temperature and SOC (remaining power) of the battery, and the battery management controller performs refined management of the power battery to ensure that the battery operates in a safe and efficient state. In this embodiment, all functions of the original battery management controller are realized by sharing a control module.

[0036] The on-board charger 22 is used to charge the power battery. When the control module 26 receives a charging request, the main circuit 27 is turned on and off according to the charging request. For example, by forming a first circuit connecting or disconnecting the power battery and the on-board charger, the operation of the on-board charger is started or stopped. In this way, the power battery is charged according to actual needs to ensure that the battery is fully charged and not overcharged.

[0037] It should be understood that the on-board charger 22 can also be designed as a "bidirectional" on-board charger according to the actual needs of the user. For example, if the on-board charger is "forward", the power battery is charged; if the on-board charger is "reverse", the external load or the power grid is discharged. This will not be elaborated here.

[0038] The DC converter 23 is used to convert the input or output DC voltage. When the control module 26 receives a voltage conversion request, the main circuit 27 is turned on and off according to the voltage conversion request. For example, by connecting or disconnecting the power battery and the second circuit of the DC converter, the operation of the DC converter is started or stopped. In this way, the conversion ratio and direction of the voltage can be flexibly adjusted to meet the voltage requirements of different equipment and loads.

[0039] It should be noted that since the main circuit 27 is shared, it includes at least two control loops, one control loop (the second loop) corresponds to the DC converter 23, and the other control loop (the first loop) corresponds to the on-board charger 22. By generating different request controls to control the on and off of different control loops, it is possible to control whether the on-board charger is working and whether the DC converter is working.

[0040] It is worth noting that the battery management controller 21, the battery collector box 25, the on-board charger 22 and the DC converter 23 share a control module 26, which greatly simplifies the control structure of the on-board power system and improves the reliability and response speed of the on-board power system; at the same time, the on-board charger 22 and the DC converter 23 share a main circuit 27, which also reduces the complexity and cost of the on-board power system.

[0041] The power distribution unit 24 realizes power distribution of multiple external high-voltage loads according to factors such as the load of the vehicle power system and user needs, thereby ensuring efficient and stable operation of the vehicle power system.

[0042] In this implementation, efficient management and energy conversion of the power battery are achieved by integrating multiple key components and sharing the control module and main circuit; at the same time, the safe and stable operation of the system is ensured by real-time monitoring of the power battery status data and adjusting the power allocation strategy.

[0043] The DC converter 23 includes a bidirectional DCDC, and the battery collector box pre-charges or actively discharges the power battery through the bidirectional DCDC.

[0044] The DC converter also includes a first switch, a second switch and a support capacitor. The positive electrode of the power battery is connected to the first end of the bidirectional DCDC through the first switch, and the negative electrode of the power battery is connected to the second end of the bidirectional DCDC through the second switch. The support capacitor is arranged outside the vehicle power system and connected in parallel to the first end and the second end. The switching states of the first switch and the second switch are adjusted based on the state data to realize the high-voltage power-on and power-off functions of the whole vehicle.

[0045] Optionally, the functions of the pre-charging circuit and the active discharging circuit are implemented based on the bidirectional DC converter to reduce the cost.

[0046] It should be understood that the pre-charging function is to protect high-voltage components from being subjected to large current shocks. When the power battery starts to charge, the system is pre-charged with a smaller current through the bidirectional DC converter 23 to ensure that each component gradually reaches the normal operating voltage, thereby avoiding damage caused by sudden large current shocks.

[0047] In addition, active discharge is to safely and quickly reduce the voltage of the power battery. For example, under normal high voltage, maintenance, battery replacement or other system operations, the voltage of the power battery needs to be reduced to a safe level; at this time, the discharge of the power battery is controlled by the bidirectional DC converter 23 to ensure the safety and controllability of the discharge process.

[0048] In this embodiment, compared with hardware design solutions such as integrating a pre-charging circuit and an active discharging circuit in a high-voltage battery pack, the present application uses a bidirectional DC converter 23, which can not only charge the power battery, but also discharge the power battery; without affecting the original functions, it not only reduces the weight and volume of the vehicle power system, but also greatly reduces the cost of the vehicle power system; when controlling the pre-charging and active discharging of the power battery, the function of the DC converter 23 is fully utilized, thereby improving the efficiency and reliability of the vehicle power system.

[0049] See also Figure 3 , showing a schematic diagram of the layout of a high-voltage power supply box in an electric vehicle provided by the present application, through

[0050] The vehicle power system integrates BMC (battery management controller), BJB (battery collector box), OBC (On-board Charger), DC / DC (direct current converter), and PDU (Power Distribution Unit) into the Power Box (high-voltage power box), and adopts a highly integrated solution to further merge the main circuit (i.e., high-voltage main circuit) and control board (i.e., control module) to save costs and achieve miniaturization and lightweight. In this way, costs can be significantly reduced and product size can be reduced.

[0051] Here, the Power Box is integrated with the electric vehicle power battery pack and located under the rear seat of the electric vehicle. Referring to the direction of the vehicle's movement, the battery cell stack in the power battery is arranged on the left, and the PowerBox in the power battery is arranged on the right. The Power Box adopts such a layout design. After removing the rear seat, the Power Box can be seen, which is convenient for subsequent repair and maintenance.

[0052] Please refer to 4, which shows a comparison diagram of the old and new vehicle power systems provided by the present application. The left part of the figure is the old vehicle power system, and the right part is the new vehicle power system. The new vehicle power system has the following advantages:

[0053] First, the BMC, BJB, OBC, DC / DC, and PDU are physically integrated together, and the original expensive high-voltage connectors, high-voltage wiring harnesses, low-voltage connectors, and low-voltage wiring harnesses are replaced by internal busbars or signal sockets. This greatly reduces the use of wiring harnesses and connectors, thereby achieving the goal of reducing costs.

[0054] Second, the BMC, BJB, OBC, DC / DC, and PDU are all physically integrated together, and the cost can be reduced by sharing the mechanical housing and cooling system.

[0055] Third, the OBC and DC / DC are physically integrated together by sharing some components of the main circuit (reusing high-voltage filter components, transformer components, power switch tubes and drivers, passive discharge components, etc.), thus achieving the purpose of reducing costs.

[0056] Fourth, the BMC, OBC, and DC / DC are physically integrated together, and the microcontroller, auxiliary power supply, CAN transceiver and other components are reused through a common control board (i.e., main control module), so as to achieve the purpose of reducing costs. Figure 4 The "3-in-1 control board" is a control module (processor) that simultaneously realizes the control and management of the battery management controller, on-board charger and DC converter.

[0057] Fifth, the BJB and DC / DC are physically integrated together, and the existing DC / DC is changed from "unidirectional DC / DC" to "bidirectional DC / DC". The "pre-charging" function and "active discharging" function are realized through the bidirectional DC / DC, so as to eliminate the pre-charging circuit and active discharging circuit in the original BJB circuit.

[0058] Through the above method, compared with the original vehicle power supply system, the vehicle power supply system corresponding to the new solution has a main circuit including a high-voltage filter component, a transformer component, a power switch tube, a drive and a discharge component that are reused by the vehicle charger and the DC converter.

[0059] Optionally, in some embodiments, the main circuit is an integrated vehicle charger, including multiplexing devices required for the operation of the DC converter, and the multiplexing devices include a high-voltage filter component, a transformer component, a power switch tube, a drive component and a discharge component.

[0060] Right now Figure 4The 2-in-1 main circuit in the vehicle charger realizes the functional reuse of the on-board charger (OBC) and the DC converter (DCDC), simplifies the circuit structure, and improves energy efficiency. For example, the high-voltage filter component is used to filter out high-frequency noise and interference on the high-voltage battery port side to ensure the stable operation of the circuit. When the OBC and DCDC are working, the high-voltage filter can work effectively to filter out interference on the high-voltage battery port side.

[0061] Transformer assembly, when OBC and DCDC are working, the transformer is used for electrical isolation and voltage regulation to meet the needs of different electrical systems of the vehicle.

[0062] The power switch tube acts as a switch in the circuit, controlling the on and off of the current to achieve efficient conversion of electrical energy. The power switch tube can quickly respond to control signals and accurately control the flow of current when working in OBC and DCDC.

[0063] The driver component provides control signals for the power switch tubes to ensure that they work according to the predetermined timing and logic. The design of the driver component takes into account the different working requirements of OBC and DCDC, and can generate corresponding control signals to achieve seamless switching of functions.

[0064] The discharge component safely discharges the residual charge in the circuit when necessary to prevent electric shock or other safety problems. The discharge component generally works after the vehicle is powered on at high voltage to ensure the safety of the circuit.

[0065] In this embodiment, the functional multiplexing of OBC and DCDC is achieved through close cooperation in the 2-in-1 main circuit. This design not only reduces the cost of hardware, but also reduces the size of the hardware.

[0066] In other embodiments, when the battery management controller, the on-board charger and the DC converter share a control module, multiplexing components such as the microcontroller, the auxiliary power supply and the CAN transceiver is an efficient and economical solution. This design strategy not only simplifies the circuit structure, reduces the hardware complexity and reduces the cost, but also improves the system integration and reliability.

[0067] Microcontroller multiplexing: On a shared control board (i.e., control module), a high-performance MCU can simultaneously manage the functions of BMC, OBC, and DC / DC, and can perform different tasks through programming and configuration, including battery status monitoring, charging control, DC voltage conversion, etc.

[0068] Reusing MCU reduces hardware costs. In addition, a unified control strategy helps optimize overall performance and ensures coordinated work among various modules.

[0069] Auxiliary power multiplexing: Provides stable power supply for all components on the control board. Through optimized design, it can meet the power requirements of BMC, OBC and DC / DC.

[0070] Reusing auxiliary power reduces the number of power modules and reduces costs. At the same time, unified power management also helps ensure system reliability.

[0071] CAN transceiver multiplexing: CAN bus is an important communication protocol within the vehicle, used to realize data transmission and coordination between different modules. Multiplexing CAN transceivers simplifies the communication interface and reduces the complexity of wiring. At the same time, the high-speed, real-time and reliable characteristics of CAN bus ensure the accuracy and efficiency of data transmission.

[0072] Through the above method, on the one hand, the number of components is reduced, the material cost is reduced, and the maintenance and replacement of parts are made simpler and more efficient, thereby achieving the purpose of reducing maintenance costs; on the other hand, the circuit structure is simplified, the potential failure points are reduced, and the overall reliability of the vehicle power system is improved; on the other hand, the shared control panel design makes it easier and more flexible to upgrade or expand the system in the future, which facilitates upgrades and expansions.

[0073] Optionally, in certain embodiments of the first aspect of the present application, the control module is a multi-core microcontroller having multiple processing cores, and the multi-core microcontroller is configured to respond to a task request by calling a processing core that matches the task request type to respond, and the task request types generated by the battery management controller, the on-board charger and the DC converter are different.

[0074] Among them, the control module adopts a multi-core architecture with high flexibility and scalability. It can increase or decrease the number of processing cores according to the number of processing tasks requested to adapt to application scenarios of different scales and complexities.

[0075] For example, the battery management controller generates task requests related to battery health, charging status, temperature control, etc.; the on-board charger generates task requests related to charging protocol, current / voltage regulation, fault detection, etc.; the DC converter generates task requests related to voltage conversion, power distribution, efficiency optimization, etc.

[0076] The multi-core microcontroller calls the corresponding processing core to respond according to the type and priority of the task request. For example, each processing core may have its own specific functions and performance characteristics to adapt to different types of task requests. For example, one processing core is good at processing tasks with high real-time requirements (such as rapid response to battery temperature), while another processing core is more suitable for processing complex algorithms and computing tasks (such as updating battery management strategies). Therefore, matching the right processing core can greatly improve the efficiency of the multi-core microcontroller.

[0077] Specifically, the multi-core microcontroller configures the priority level of each processing core according to the processing performance of each processing core, and responds by matching the processing core of the corresponding priority level according to the priority of the type of the received task request; wherein, the priority of the task request type corresponds to the priority of the processing core one by one, and if any of the task request matches one of the processing cores, the processing core is called to respond; if any of the task request matches multiple processing cores at the same time, the processing core with the least number of task request queues is selected to respond; if any of the task request matches only one of the processing cores, and the number of task request queues currently mounted on the processing core exceeds a preset threshold, the processing core with a priority higher than the priority corresponding to the current task request is selected to respond.

[0078] In the above manner, task requests are matched with processing cores to ensure efficient use of multi-core microcontroller resources and optimal performance, which helps reduce task processing delays and improve the overall response speed of the vehicle power system. If a processing core is currently heavily loaded, the multi-core microcontroller can intelligently assign task requests to other idle or lightly loaded processing cores to maintain the balance and stability of the vehicle power system; at the same time, in order to ensure the security of task request execution, a processing core with a higher priority than the current task request is selected, thereby also ensuring the security of the vehicle power system.

[0079] In this embodiment, since a large number of components of the original independent products are reused, the product cost, product volume, and product weight are significantly optimized, meeting the requirements of low cost, miniaturization, and lightweight. At the same time, since the PDU originally designed for passive heat dissipation is also integrated into the Power Box and shares the cooling system, the heat dissipation characteristics of the PDU are greatly enhanced, making it compatible with super-fast charging with a larger current, thereby improving the charging efficiency of the entire vehicle.

[0080] See also Figure 5, which is a comparison diagram of a new and old pre-charge and discharge scheme provided in the present application. The new pre-charge and discharge scheme includes: a bidirectional DCDC, a first switch, a second switch and a support capacitor. The positive electrode of the power battery is connected to the first end of the bidirectional DCDC through the first switch, and the negative electrode of the power battery is connected to the second end of the bidirectional DCDC through the second switch. The support capacitor is connected in parallel to the first end and the second end.

[0081] Among them, the first switch and the second switch are used to control the on-off between the power battery and the DCDC converter, because the bidirectional DCDC needs the first switch and the second switch to be in the "off" state when realizing "pre-charging" and "active discharging". The energy is transferred from the 12V low-voltage battery to the high-voltage support capacitor through the bidirectional DCDC, so that the voltage of the support capacitor is basically consistent with the power battery voltage (corresponding to the "pre-charging mode"); the high-voltage energy is transferred from the support capacitor to the 12V low-voltage battery or directly consumed in the DCDC switch tube through the bidirectional DCDC, so that the voltage of the support capacitor is lower than the 60VDC safety voltage (corresponding to the "active discharge mode"), thereby assisting the vehicle to realize high-voltage power-on and power-off.

[0082] It should be noted that the support capacitor is connected in parallel between the first and second terminals of the DCDC converter. Here, the support capacitor is arranged outside the vehicle power system and is generally integrated into the vehicle electric drive system. For example, the 12V battery is always connected in parallel to the low-voltage side of the DCDC, and the high-voltage side of the DCDC is connected to the power battery through a "switch".

[0083] It should also be noted that the DCDC converter can realize bidirectional conversion of DC voltage, that is, increase or decrease the voltage of the 12V low-voltage battery to meet the needs of different loads; at the same time, the 12V low-voltage battery voltage is converted into a voltage that the supporting capacitor can receive, realizing bidirectional flow of energy.

[0084] In this embodiment, compared with the existing pre-charging and active discharging scheme, the new pre-charging and active discharging scheme changes the "unidirectional DC / DC" to "bidirectional DC / DC", and at the same time, eliminates the pre-charging circuit and the discharge circuit in the original BJB (battery collector box) circuit, thus significantly reducing the cost and weight of the BJB.

[0085] The high-voltage power supply box is integrated into the battery pack where the power battery is located, or the high-voltage power supply box is directly covered on the (high-voltage) battery pack or covered on the outside of the battery pack through an installation interface.

[0086] Specifically, the Power Box can be integrated directly into the high-voltage battery pack without a shell; or it can have its own shell and directly cover the high-voltage battery pack through the installation interface.

[0087] Optionally, the battery management controller, the battery collector box, the on-board charger, the DC converter and the power distribution unit share a cooling system.

[0088] Specifically, if the high-voltage power supply box is integrated into the battery pack where the power battery is located, the power battery shares a cooling system with the battery management controller, the battery collector box, the on-board charger, the DC converter, and the power distribution unit.

[0089] For example, the cooling system includes at least one of air cooling, water cooling, oil cooling, gas cooling and phase change cooling. Air cooling is to blow air through the heat-generating components through a fan to take away the heat in the high-voltage power supply box; water cooling is to circulate coolant in a closed pipe to take away the heat in the high-voltage power supply box through a heat exchanger; air cooling is to use gas (such as nitrogen) for cooling; phase change cooling is to use the property of a substance to absorb or release a large amount of heat during a phase change (such as from liquid to solid) to take away the heat in the high-voltage power supply box.

[0090] See also Figure 6 , is a cooling schematic diagram of a vehicle power system provided by this application, which is described in detail as follows:

[0091] The Power Box is only a module of the entire (high-voltage) battery pack. The Power Box can reuse the cooling water channel of the high-voltage battery pack, or design an independent cooling water channel to improve the layout of the Power Box in the high-voltage battery pack, such as Figure 6 As shown, the Power Box with an independent cooling water channel can also be stacked on the battery cell stack, making the layout more flexible.

[0092] Among them, the fast charging relay in the BJB is changed from "two" to "one" (eliminating the "high-voltage positive relay" or "high-voltage negative relay"), which reduces the cost and miniaturizes it;

[0093] It should be noted that the OBC and DC / DC are changed from being configured with a separate mechanical fuse to sharing a mechanical fuse to reduce costs and miniaturization.

[0094] It should also be noted that the high-voltage air conditioner and the high-voltage PTC are changed from being configured with a separate mechanical fuse to sharing a mechanical fuse to reduce costs and miniaturization.

[0095] The vehicle power supply system in the present application integrates a battery management controller, a battery collector box, an on-board charger, a DC converter and a power distribution unit into a high-voltage power supply box, and the battery management controller, the on-board charger and the DC converter share a control module, and the on-board charger and the DC converter share a main circuit. On the one hand, by reusing the same components, the components are greatly reduced without affecting the original performance; on the other hand, by improving the integration of the on-board power supply system, the cost of the on-board power supply system is reduced, the size and volume of the on-board power supply system are reduced, and at the same time, the weight of the on-board power supply system is reduced, and the working efficiency of the on-board power supply system is improved.

[0096] See also Figure 7 , is a flow chart of a control method based on a vehicle power system provided by the present application, wherein the vehicle power system includes a power battery, a high-voltage power supply box electrically connected to the power battery, and a battery management controller, a battery collector box, an on-board charger, a DC converter and a power distribution unit integrated in the high-voltage power supply box, and directly connected to the high-voltage busbar between the power battery; the battery management controller, the on-board charger and the DC converter share a control module, and the on-board charger and the DC converter share a main circuit; wherein the control method includes:

[0097] Step S701, using the control module to monitor the status data of the power battery in real time, and managing the power battery according to the status data, so that the power distribution unit completes the power distribution of the external high-voltage load;

[0098] Step S702: if a charging request is received, a first circuit connecting the power battery and the on-board charger is formed through the main circuit to charge the power battery;

[0099] Step S703: If a voltage conversion request is received, a second loop connecting the power battery and the DC converter is formed through the main circuit to perform voltage conversion on the input or output DC voltage.

[0100] It should also be noted that there is a one-to-one correspondence between the vehicle power system and the control method based on the vehicle power system. Here, the technical details and technical effects involved in the control method based on the vehicle power system are the same as those of the above-mentioned vehicle power system, and will not be described one by one here. Please refer to the above-mentioned vehicle power system.

[0101] The present application is based on a control method for a vehicle-mounted power supply system, by integrating a battery management controller, a battery collector box, an on-board charger, a DC converter and a power distribution unit in a high-voltage power supply box, and at the same time, the battery management controller, the on-board charger and the DC converter share a control module, and the on-board charger and the DC converter share a main circuit. On the one hand, by reusing the same components, the components are greatly reduced without affecting the original performance; on the other hand, by improving the integration of the on-board power supply system, the cost of the on-board power supply system is reduced, the size and volume of the on-board power supply system are reduced, and at the same time, the weight of the on-board power supply system is reduced, and the working efficiency of the on-board power supply system is also improved.

[0102] In another embodiment of the present invention, the embodiment further provides an electric vehicle for executing the on-board power supply system as described in some or a certain embodiment above, which will not be described in detail here.

[0103] The above embodiments are merely illustrative of the principles and effects of the present application and are not intended to limit the present application. Anyone familiar with the technology may modify or change the above embodiments without violating the spirit and scope of the present application. Therefore, all equivalent modifications or changes made by a person of ordinary skill in the art without departing from the spirit and technical ideas disclosed in the present application shall still be covered by the claims of the present application.

Claims

1. A vehicle power supply system, characterized in that: It includes a power battery, a high-voltage power supply box electrically connected to the power battery, and a battery management controller, a battery collector box, an on-board charger, a DC converter and a power distribution unit integrated in the high-voltage power supply box; The battery management controller, the on-board charger and the DC converter share a control module, and the on-board charger and the DC converter share a main circuit; the control module is configured to, if a charging request is received, form a first circuit connecting the power battery and the on-board charger through the main circuit to charge the power battery; if a voltage conversion request is received, form a second circuit connecting the power battery and the DC converter through the main circuit to perform voltage conversion on the input or output DC voltage; The control module is further configured to monitor the status data of the power battery in real time, and manage the power battery according to the status data so that the power distribution unit completes power distribution.

2. The vehicle-mounted power supply system according to claim 1, characterized in that: The control module includes a multi-core microcontroller with multiple processing cores, and the multi-core microcontroller is configured to respond to a task request by calling a processing core that matches the task request type to respond. The task request types generated by the battery management controller, the on-board charger and the DC converter are different.

3. The vehicle-mounted power supply system according to claim 2, characterized in that: The multi-core microcontroller configures the priority level of each processing core according to the processing performance of each processing core, and responds by matching the processing core of the corresponding priority level according to the priority of the type of the received task request; wherein, the priority of the task request type corresponds to the priority of the processing core one by one, and if any of the task requests matches one of the processing cores, the processing core is called to respond; if any of the task requests matches multiple processing cores at the same time, the processing core with the least number of task request queues is selected to respond; if any of the task requests matches only one of the processing cores, and the number of task request queues currently mounted on the processing core exceeds a preset threshold, the processing core with a priority higher than the priority corresponding to the current task request is selected to respond.

4. The vehicle-mounted power supply system according to claim 1, characterized in that: The DC converter includes a bidirectional DCDC, and the battery collector box pre-charges or actively discharges the power battery through the bidirectional DCDC.

5. The vehicle-mounted power supply system according to claim 4, characterized in that: The DC converter also includes a first switch, a second switch and a support capacitor. The positive electrode of the power battery is connected to the first end of the bidirectional DCDC through the first switch, and the negative electrode of the power battery is connected to the second end of the bidirectional DCDC through the second switch. The support capacitor is arranged outside the vehicle power system and is connected in parallel between the first end and the second end.

6. The vehicle-mounted power supply system according to claim 1, characterized in that: The battery management controller, the battery collector box, the on-board charger, the DC converter and the power distribution unit share a cooling system, and the cooling system includes at least one of air cooling, water cooling, oil cooling, gas cooling and phase change cooling.

7. The vehicle-mounted power supply system according to claim 1, characterized in that: The high-voltage power supply box is integrated into the battery pack where the power battery is located, or the high-voltage power supply box is covered on top of the battery pack through an installation interface.

8. The vehicle-mounted power supply system according to claim 7, characterized in that: If the high-voltage power supply box is integrated into the battery pack where the power battery is located, the power battery shares a cooling system with the battery management controller, the battery collector box, the on-board charger, the DC converter, and the power distribution unit.

9. The vehicle-mounted power supply system according to any one of claims 1 to 7, characterized in that: The battery management controller, the battery collector box, the on-board charger, the DC converter and the power distribution unit are integrated in the high-voltage power supply box via a signal socket or a high-voltage busbar.

10. A control method for a vehicle power system, characterized in that: The vehicle power supply system includes a power battery, a high-voltage power supply box electrically connected to the power battery, and a battery management controller, a battery collector box, a vehicle charger, a DC converter and a power distribution unit integrated in the high-voltage power supply box; the battery management controller, the vehicle charger and the DC converter share a control module, and the vehicle charger and the DC converter share a main circuit; wherein the control method includes: Using the control module to monitor the status data of the power battery in real time, and managing the power battery according to the status data, so that the power distribution unit completes the power distribution of the external high-voltage load; If a charging request is received, a first circuit connecting the power battery and the on-board charger is formed through the main circuit to charge the power battery; If a voltage conversion request is received, a second loop connecting the power battery and the DC converter is formed through the main circuit to perform voltage conversion on the input or output DC voltage.

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