Power distribution box, power distribution box assembly method, power assembly and vehicle

Abstract

The present application provides a distribution box, a method for assembling a distribution box, a powertrain, and a vehicle. The distribution box includes a box body; a plurality of electronic components that can be detachably installed inside the box body, and a pin is provided on the top of each of the electronic components; a lead member is provided above each of the electronic components, and a conductive lead is embedded inside the lead member, and the pins of each of the electronic components are fixedly connected to the lead member and electrically connected to the conductive lead. The distribution box, the method for assembling a distribution box, the powertrain, and the vehicle provided by the present application can effectively improve the overall assembly efficiency of the distribution box.

Description

Technical Field

[0001] The present application relates to the field of vehicle technology, and in particular to a distribution box, an assembly method of a distribution box, a power assembly and a vehicle. Background Art

[0002] The power distribution box is an important part of the vehicle. The power distribution box includes a box body and a large number of electronic components arranged inside the box body. The electronic components are connected by wire harnesses to achieve electrical connection.

[0003] The wiring harness has a certain degree of flexibility. When laying the wiring harness, it is necessary to reserve a laying space for the wiring harness inside the shell around each electronic component, and then manually organize the wiring harness to complete the positioning and connection of the wiring harness, resulting in low overall assembly efficiency of the distribution box. Summary of the invention

[0004] The present application provides a distribution box, an assembly method of a distribution box, a power assembly and a vehicle, which can effectively improve the overall assembly efficiency of the distribution box.

[0005] The present application provides a power distribution box, wherein the power distribution box comprises:

[0006] Box body;

[0007] A plurality of electronic components are detachably installed inside the box body, and a pin is provided on the top of each of the electronic components;

[0008] A lead member is arranged above each of the electronic components, a conductive lead is embedded in the lead member, a pin of each of the electronic components is fixedly connected to the lead member, and the pin of each of the electronic components is electrically connected to the conductive lead.

[0009] The distribution box as described above, wherein the distribution box also includes a connecting bar assembly, a portion of which is fixedly connected to the box body, and a portion of which extends to the outside of the box body to form a connecting terminal, and at least part of the electronic components is electrically connected to the connecting bar assembly.

[0010] The power distribution box as described above, wherein the electronic components include a pre-charge relay, a pre-charge resistor and a plurality of main relays;

[0011] The pre-charging relay and the pre-charging resistor are both connected to the lead member;

[0012] Each of the main relays is connected to the lead member and the connection bar assembly respectively.

[0013] The distribution box as described above, wherein the lead assembly includes a circuit board, a hole structure is provided on the circuit board corresponding to each of the electronic components, the conductive lead is buried in a position on the circuit board where the hole structure is not provided, a lead terminal is protruding on the hole wall of the hole structure, the lead terminal is electrically connected to the conductive lead, and each of the electronic components is fixedly connected and electrically connected to the lead terminal at the corresponding hole structure.

[0014] In the distribution box as described above, a plurality of voltage detection terminals are connected to the periphery of the circuit board, each of the voltage detection terminals is electrically connected to one of the connection terminals, and the voltage detection terminals are configured to detect the voltage at the corresponding connection terminal.

[0015] The power distribution box as described above, wherein the voltage detection terminal is fixedly connected to the circuit board;

[0016] And / or, a connection port is provided on the circuit board, and the lead member further comprises an external detection element, the external detection element is fixedly connected to the connection port and connected to the box body, and the external detection element is provided with at least one voltage detection terminal.

[0017] In the power distribution box as described above, at least part of the voltage detection terminals are connected with temperature sensors.

[0018] In the distribution box as described above, positioning holes are provided on the circuit board, and positioning pieces are provided on top of at least some of the electronic components, and the positioning pieces are plugged into the positioning holes for positioning.

[0019] The power distribution box as described above, wherein the pins of the electronic components are arranged vertically, and the power distribution box further comprises an adapter, the adapter is formed with a first connection surface facing upward, the pins are plugged and fixed to the adapter and are electrically connected to the first connection surface, and the first connection surface is welded and fixed to the lead member;

[0020] And / or, the pin is horizontally arranged and has a second connection surface facing upward, and the second connection surface is welded and fixed to the lead member.

[0021] In the distribution box as described above, the pre-charging relay and the pre-charging resistor are respectively connected and electrically connected to the lead component through the adapter; and each main relay is directly connected and electrically connected to the lead component.

[0022] The power distribution box as described above, wherein each of the main relays comprises a main positive relay, a main negative relay, a fast charge positive relay, a fast charge negative relay and a boost relay;

[0023] The connecting bar assembly includes a first connecting bar, a second connecting bar, a third connecting bar, a fourth connecting bar, a fifth connecting bar and a sixth connecting bar which are independent of each other;

[0024] The connection terminals include a positive power connection terminal, a negative power connection terminal, a positive power output terminal, a negative power output terminal, a fast charge positive connection terminal, a fast charge negative connection terminal and a boost positive connection terminal;

[0025] One end of the first connection row forms the positive power connection terminal, and the other end of the first connection row is respectively connected to the main positive relay and the fast charging positive relay, the main positive relay and the fast charging positive relay are arranged in parallel, and are both connected to the second connection row, one end of the second connection row forms the positive power output terminal, and the other end of the second connection row forms the fast charging positive connection terminal, the boost relay is respectively connected to one end of the second connection row and the third connection row, and the other end of the third connection row forms the boost positive connection terminal;

[0026] One end of the fourth connection row forms the negative electrode of the power supply to connect electrons, the other end of the fourth connection row is connected to the main negative relay, the main negative relay is connected to one end of the fifth connection row, the other end of the fifth connection row forms the negative electrode output terminal of the power supply, the fast charging negative relay is respectively connected to one end of the fourth connection row and the sixth connection row, and the other end of the sixth connection row forms the fast charging negative electrode connection terminal.

[0027] As described above, the distribution box, wherein the pre-charging relay and the pre-charging resistor are connected in series through the conductive lead, and the pre-charging relay is electrically connected to the positive connection terminal of the power supply through the conductive lead, and the pre-charging resistor is electrically connected to the positive output terminal of the power supply through the conductive lead.

[0028] In the power distribution box as described above, a temperature sensor is connected to the positive power connection terminal and the positive power output terminal.

[0029] The power distribution box as described above, wherein the box body comprises a bottom box and a top box, and the bottom box and the top box are detachably connected;

[0030] The bottom box includes a bottom plate, side walls and partitions, a portion of the connection row assembly is buried inside the bottom plate and / or the side walls, and a portion of the connection row assembly extends from the top of the bottom box to the outside thereof to form the connection terminal; the partition is arranged inside the bottom box and connected to the bottom plate and / or the side walls, and the interior of the bottom box is divided by the partitions to form a plurality of accommodating spaces, and a portion of each of the electronic components is correspondingly inserted in one of the accommodating spaces.

[0031] As described above, in the distribution box, the pre-charging relay and the pre-charging resistor are detachably connected to the position of the bottom plate where the connecting row assembly is not embedded through connecting parts; each of the main relays is detachably connected to the position of the bottom plate where the connecting row assembly is embedded through connecting parts.

[0032] The power distribution box as described above, wherein a portion of the connection bar assembly is exposed on the lower surface of the bottom plate;

[0033] The power distribution box further comprises an insulating film and a thermal pad, wherein the insulating film covers the exposed area of ​​the connection row assembly on the lower surface of the bottom plate, and the thermal pad is disposed on a side of the insulating film away from the box body.

[0034] As described above, the distribution box further comprises a battery management unit, wherein the battery management unit comprises a circuit assembly and a housing, wherein the housing is detachably mounted on the top surface of the box body, wherein the housing and the top surface of the box body are combined to form an installation cavity, wherein the circuit assembly is disposed inside the installation cavity.

[0035] The present application also provides a method for assembling a power distribution box, wherein the method for assembling a power distribution box is used to assemble the power distribution box as described above, and the method for assembling a power distribution box comprises:

[0036] Set up the box body;

[0037] Placing electronic components inside the box body, and connecting a portion of the electronic components and the first portion of the lead member to the box body through a connector;

[0038] Press the electronic components tightly inside the box body, turn over the box body, connect another part of the electronic components to the box body through a connector, and turn over the box body again;

[0039] A second portion of the lead member is provided, the second portion of the lead member is connected to the first portion of the lead member, and each of the electronic components is connected to the second portion of the lead member.

[0040] In the above-mentioned method for assembling a power distribution box, the step of setting the box body comprises:

[0041] The connecting row assembly is formed with the bottom box of the box body by injection molding. The box body includes an integrally formed bottom plate, side walls and partitions. The partitions divide the interior of the box body into a plurality of accommodating spaces.

[0042] The method for assembling the power distribution box as described above, wherein the electronic components are arranged inside the box body, and a part of the electronic components and the first part of the lead member are connected to the box body through a connector, comprising:

[0043] The pre-charging relay, the pre-charging resistor and the plurality of main relays are arranged inside the box body, and at least a part of each of the electronic components is correspondingly inserted into one of the accommodating spaces;

[0044] An external detection element is provided for the lead member;

[0045] The pre-charging relay, the pre-charging resistor and the external detection element are detachably connected to the box body through the connecting piece.

[0046] The method for assembling the power distribution box as described above, wherein the electronic components are pressed tightly against the inside of the box body, the box body is turned over, another part of the electronic components is connected to the box body through a connector, and the box body is turned over again, comprising:

[0047] Compressing each of the main relays by means of a pressing tool;

[0048] Turn the box body 180° so that the bottom of the box body faces upward;

[0049] Each of the main relays is detachably connected to the box body through the connecting piece;

[0050] The box body is turned over 180°.

[0051] The method for assembling the power distribution box as described above, wherein the second part of the lead member is provided, the second part of the lead member is connected to the first part of the lead member, and each of the electronic components is connected to the second part of the lead member, comprising:

[0052] Arranging a circuit board above each of the electronic components;

[0053] Connecting and electrically connecting the external detection element to the circuit board;

[0054] Each of the electronic components is electrically connected to the circuit board.

[0055] The method for assembling a power distribution box as described above, wherein the method for assembling a power distribution box further comprises:

[0056] A top box is arranged above the bottom box, and the top box is detachably connected to the bottom box;

[0057] A battery management unit is arranged above the top box, and the battery management unit is detachably connected to the upper surface of the top box.

[0058] The present application also provides a powertrain, wherein the powertrain includes the distribution box as described above.

[0059] The present application also provides a vehicle, wherein the vehicle includes the distribution box or powertrain as described above.

[0060] The distribution box, the assembly method of the distribution box, the power assembly and the vehicle provided in the embodiments of the present application use lead components to achieve the structural connection and electrical connection of each electronic component. The lead components replace the flexible wiring harness. The lead components can be connected to each electronic component through an assembly production line, thereby realizing automated assembly and effectively improving assembly efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0061] Figure 1 A schematic diagram of the structure of a power distribution box provided in an embodiment of the present application;

[0062] Figure 2 An exploded view of a power distribution box provided in an embodiment of the present application;

[0063] Figure 3 A cross-sectional view of a power distribution box provided in an embodiment of the present application;

[0064] Figure 4 An internal top view of a power distribution box provided in an embodiment of the present application;

[0065] Figure 5 A schematic diagram of the electrical connection structure of the electronic components of the power distribution box provided in an embodiment of the present application;

[0066] Figure 6 A schematic diagram of the structure of an external detection element of a lead member of a power distribution box provided in an embodiment of the present application;

[0067] Figure 7 A schematic diagram of the structure of a main relay of a power distribution box provided in an embodiment of the present application;

[0068] Figure 8 An exploded view of a pre-charge relay and a adapter of a power distribution box provided in an embodiment of the present application;

[0069] Fig. 9 An exploded view of the pre-charging resistor and its adapter of the power distribution box provided in an embodiment of the present application;

[0070] Fig.10 A layout diagram of the electronic components of the power distribution box provided in an embodiment of the present application inside the base box;

[0071] Fig.11 A schematic diagram of the connection between the main relay and the connection bar assembly of the power distribution box provided in an embodiment of the present application;

[0072] Fig.12 A high voltage schematic diagram of a power distribution box provided in an embodiment of the present application;

[0073] Fig.13 A schematic diagram of the cooling conduction path of the distribution box provided in an embodiment of the present application.

[0074] Description of Figure Numbers:

[0075] 1. box body; 11. bottom box; 111. bottom plate; 112. side wall; 113. partition; 12. top cover;

[0076] 2. Electronic components; 21. Pre-charge relay; 22. Pre-charge resistor; 23. Main relay; 231. Positioning piece; 232. Main positive relay; 233. Main negative relay; 234. Fast charge positive relay; 235. Fast charge negative relay; 236. Boost relay; 237. Second connection surface; 24. Pins;

[0077] 3. Lead member; 31. Circuit board; 311. Hole structure; 3111. Lead terminal; 312. Connecting port; 313. Positioning hole; 32. Voltage detection terminal; 33. External detection element; 34. Temperature sensor;

[0078] 4. Connecting row assembly; 41. First connecting row; 411. Power positive connecting terminal; 42. Second connecting row; 421. Power positive output terminal; 422. Fast charging positive connecting terminal; 43. Third connecting row; 431. Boost positive connecting terminal; 44. Fourth connecting row; 441. Power negative connecting terminal; 45. Fifth connecting row; 451. Power negative output terminal; 46. Sixth connecting row; 461. Fast charging negative connecting terminal; 47. Shunt;

[0079] 5. Insulation film;

[0080] 6. Thermal pad;

[0081] 7. Battery management unit; 71. Housing; 72. Circuit assembly;

[0082] 8. Cooling plate;

[0083] 9. Adapter; 91. First connecting surface. DETAILED DESCRIPTION

[0084] In order to more clearly understand the above-mentioned objectives, features and advantages of the present disclosure, the scheme of the present disclosure will be further described below. It should be noted that the embodiments of the present disclosure and the features in the embodiments can be combined with each other without conflict.

[0085] In the following description, many specific details are set forth to facilitate a full understanding of the present disclosure, but the present disclosure may also be implemented in other ways different from those described herein; it is obvious that the embodiments in the specification are only part of the embodiments of the present disclosure, rather than all of the embodiments.

[0086] It should be noted that, in this article, 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 term "comprises" or any other variant thereof is 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 existence of other identical elements in the process, method, article or device including the elements.

[0087] The high-voltage distribution box is the battery energy distribution unit on the high-voltage circuit of an electric vehicle. In the industry, the high-voltage distribution box in the power battery is called a BDU (Battery Disconnect Unit). At present, BDUs in the industry are generally manually produced on flexible production lines, that is, they are equipped with a large number of flexible wiring harnesses, which need to be assembled manually. On the one hand, this leads to low production efficiency and high unit product cost of BDUs. On the other hand, it leads to low integration of BDUs, which is not conducive to their miniaturization. In addition, when the battery is charged and discharged at a high rate, the temperature of the electronic components 2 inside the BDU is high and difficult to monitor.

[0088] Therefore, the present application provides a distribution box, aiming to solve the problems existing in the above-mentioned prior art.

[0089] like Figures 1 to 3 As shown, the present application provides a distribution box, wherein the distribution box includes a box body 1, a plurality of electronic components 2 and a lead member 3.

[0090] A sealed accommodating cavity is formed inside the box body 1 ; a plurality of electronic components 2 can be detachably installed inside the box body 1 , and a pin 24 is provided on the top of each electronic component 2 for realizing electrical connection of each electronic component 2 .

[0091] The lead member 3 is arranged above each electronic component 2. Along the arrangement direction of the lead member 3 and the electronic component 2, the projection of the pin 24 of the electronic component 2 falls into the projection of the lead member 3 to ensure that each electronic component 2 can be smoothly connected to the lead member 3. The pin 24 of each electronic component 2 is fixedly connected to the lead member 3 by welding to ensure the connection strength between the electronic component 2 and the lead member 3. A conductive lead is buried inside the lead member 3, and the pin 24 of each electronic component 2 is electrically connected to the conductive lead to achieve electrical connection of each electronic component 2. The lead member 3 includes multiple functions such as voltage acquisition, temperature acquisition, control of the pin 24 of the electronic component 2, and external connection of other components.

[0092] The distribution box provided in the embodiment of the present application adopts a lead member 3 to realize the structural connection and electrical connection of each electronic component 2. The lead member 3 replaces the flexible wiring harness in the prior art. The lead member 3 can complete the connection relationship with each electronic component 2 through an assembly production line, thereby realizing automated assembly and eliminating the manual assembly process, which can effectively improve the assembly efficiency and reduce the labor cost; and it can eliminate the installation space reserved for the flexible wiring harness inside the existing distribution box, effectively improve the integration of the distribution box, and is conducive to the miniaturization of the distribution box.

[0093] like Figures 2 to 5 As shown, the power distribution box provided by the present application, wherein the power distribution box further comprises a connection row assembly 4, and at least part of the electronic components 2 are electrically connected to the connection row assembly 4, so as to realize high-voltage connection of each electronic component 2 through the connection row assembly 4 to form a high-voltage circuit. A part of the connection row assembly 4 is fixedly connected to the box body 1, and a part of the connection row assembly 4 extends to the outside of the box body 1 to form a connection terminal, and the connection terminal is used to connect with other structural components outside the box body 1, such as a power battery.

[0094] like Figure 2 and Figure 5 As shown, the distribution box provided by the present application, wherein the electronic components 2 include a pre-charge relay 21, a pre-charge resistor 22 and a plurality of main relays 23; the pre-charge relay 21 and the pre-charge resistor 22 are both connected to the lead component 3; each main relay 23 is respectively connected to the lead component 3 and the connecting row assembly 4 to form a complete circuit structure inside the distribution box.

[0095] The pre-charging relay 21 is used to realize the opening and closing of the pre-charging function; the main function of the pre-charging resistor 22 is to form an RC loop with the X capacitor of the whole vehicle to achieve the purpose of pre-charging.

[0096] like Figure 2As shown, the distribution box provided by the present application, wherein the lead member 3 includes a circuit board 31, the circuit board 31 is similar to a circuit board, and a hole structure 311 is provided on the circuit board 31 corresponding to each electronic component 2, and the conductive lead is buried in a position where the hole structure 311 is not provided on the circuit board 31 to ensure the continuity of the conductive lead. A lead terminal 3111 is convexly provided on the hole wall of the hole structure 311, and the lead terminal 3111 is electrically connected to the conductive lead. Each electronic component 2 is fixedly connected and electrically connected to the lead terminal 3111 at the corresponding hole structure 311, so as to realize the structural positioning between the electronic component 2 and the lead member 3 and the conduction of the circuit.

[0097] like Figures 2 to 5 As shown, the distribution box provided by the present application has a plurality of voltage detection terminals 32 connected to the periphery of a circuit board 31, each voltage detection terminal 32 is electrically connected to a connection terminal, and the two can be in contact connection, and the voltage detection terminal 32 is configured to detect the voltage at the corresponding connection terminal, so that the voltage at each connection terminal of the distribution box can be detected in real time to monitor whether the distribution box is in a normal state, and when the voltage of the distribution box is abnormal, it can be discovered in time to carry out maintenance.

[0098] In the power distribution box provided in the present application, the voltage detection terminal 32 is fixedly connected to the circuit board 31 to ensure the reliability of the connection between the two.

[0099] like Figures 2 to 5 As shown, the distribution box provided by the present application, wherein a connection port 312 is provided on one side of the circuit board 31, and the lead member 3 also includes an external detection element 33, and the external detection element 33 is welded and fixed to the connection port 312 and connected to the box body 1, so as to indirectly connect the circuit board 31 to the box body 1, and fix the relative positions of the circuit board 31 and each electronic component 2.

[0100] The external detection element 33 is provided with at least one voltage detection terminal 32 . When the external detection element 33 is fixed to the connection port 312 by welding, the voltage detection terminal 32 on the external detection element 33 is electrically connected to the conductive lead on the circuit board 31 .

[0101] like Figure 2 , Figures 4 to 6 As shown, the distribution box as described above is provided in an embodiment of the present application, wherein at least part of the voltage detection terminals 32 are connected with temperature sensors 34 to detect the temperature at the corresponding connection terminals. When the distribution box is connected to the power battery and high-rate charging and discharging is performed, the temperature of the heating position in the high-voltage circuit is monitored in real time, and protective measures are taken when the temperature is too high to ensure electricity safety.

[0102] like Figure 7As shown, the distribution box provided by the present application has a positioning hole 313 formed on the circuit board 31, and a positioning piece 231 is provided on the top of at least part of the electronic components 2, and the positioning piece 231 is plugged and positioned with the positioning hole 313. In this way, the relative position between the electronic component 2 and the circuit board 31 can be maintained in the horizontal direction by the positioning and plugging of the positioning piece 231 with the positioning hole 313, so as to prevent the welding connection between the two from cracking due to stress, resulting in welding failure, and ensure the reliability of the connection end between the electronic component 2 and the circuit board 31.

[0103] Optionally, the positioning hole 313 can be shared with the hole structure 311 for achieving connection. Exemplarily, two positioning members 231 are formed on the top of each main relay 23, and two hole structures 311 can be opened on the circuit board 31 corresponding to each main relay 23. The two hole structures 311 correspond to the two pins 24 of the main relay 23, and the two positioning members 231 are respectively inserted into the two hole structures 311, and the two positioning members 231 are respectively abutted against the hole walls of the two hole structures 311 that are close to or far away from each other. The relative position between the main relay 23 and the circuit board 31 is maintained by the cooperation of the two positioning members 231 and the two hole structures 311.

[0104] like Figure 8 and Fig. 9 As shown, the distribution box provided by the present application, wherein the pin 24 of the electronic component 2 is vertically arranged, at this time, the top end surface area of ​​the pin 24 is very small, in order to ensure the welding area between it and the lead member 3, the distribution box also includes an adapter 9, the function of the adapter 9 is mainly to lead out the pin 24 of the electronic component 2 to facilitate welding, the adapter 9 is formed with an upward first connecting surface 91, the pin 24 is plugged and fixed to the adapter 9 and is electrically connected to the first connecting surface 91, and the first connecting surface 91 is welded and fixed to the lead member 3; specifically, the area of ​​the first connecting surface 91 is much larger than the area of ​​the top end surface of the pin 24, while ensuring the effective electrical connection between the pin 24 and the first connecting surface 91, the first connecting surface 91 is welded and fixed to the lead member 3, which indirectly increases the connection area between the pin 24 and the lead member 3, thereby ensuring the effectiveness of circuit conduction.

[0105] Alternatively, the pin 24 may be arranged horizontally, so that the pin 24 has a second connection surface 237 facing upward, and the second connection surface 237 is directly welded and fixed to the lead component 3, which can also ensure the connection area between the pin 24 and the second connection surface 237.

[0106] Alternatively, if Figure 8 and Fig. 9As shown, the distribution box provided by the present application, wherein the pins 24 at the top of the pre-charging relay 21 and the pre-charging resistor 22 are vertically arranged, so the pre-charging relay 21 and the pre-charging resistor 22 are respectively connected to the lead component 3 and electrically connected through the adapter 9; the pins 24 of each main relay 23 are horizontally arranged, so each main relay 23 is directly connected to the lead component 3 and electrically connected.

[0107] like Figures 10 to 12 As shown, the distribution box provided by the present application, wherein each main relay 23 includes a main positive relay 232, a main negative relay 233, a fast charging positive relay 234, a fast charging negative relay 235 and a boost relay 236; each main relay 23 is a high-specification relay, and illustratively, the compatible model is 600A.

[0108] The connecting bar assembly 4 includes a first connecting bar 41, a second connecting bar 42, a third connecting bar 43, a fourth connecting bar 44, a fifth connecting bar 45 and a sixth connecting bar 46 which are independent of each other; each connecting bar can be a connecting piece made of a metal material with good conductivity, such as a copper bar or an aluminum bar.

[0109] The connection terminals include seven, namely, a positive power connection terminal 411, a negative power connection terminal 441, a positive power output terminal 421, a negative power output terminal 451, a fast charge positive connection terminal 422, a fast charge negative connection terminal 461 and a boost positive connection terminal 431; the positive power connection terminal 411 is connected to the positive pole of the power battery, and the negative power connection terminal 441 is connected to the negative pole of the power battery to realize electrical connection with the power power supply; the positive power output terminal 421 and the negative power output terminal 451 are used to realize the transmission of electric energy from the power battery to the electrical device; the fast charge positive connection terminal 422 and the fast charge negative connection terminal 461 cooperate to provide a fast charge function.

[0110] Specifically, one end of the first connection row 41 forms a power positive connection terminal 411, and the other end of the first connection row 41 is respectively connected to the main positive relay 232 and the fast charging positive relay 234, the main positive relay 232 and the fast charging positive relay 234 are arranged in parallel, and the main positive relay 232 and the fast charging positive relay 234 are both connected to the second connection row 42, one end of the second connection row 42 forms a power positive output terminal 421, and the other end of the second connection row 42 forms a fast charging positive connection terminal 422, and the boost relay 236 is respectively connected to the second connection row 42 and One end of the third connection row 43 is connected, and the other end of the third connection row 43 forms a boost positive connection terminal 431; one end of the fourth connection row 44 forms a negative power supply connection electron, and the other end of the fourth connection row 44 is connected to the main negative relay 233, and the main negative relay 233 is connected to one end of the fifth connection row, so the other end of the fifth connection row 45 forms a negative power supply output terminal 451, and the fast charging negative relay 235 is respectively connected to one end of the fourth connection row 44 and the sixth connection row 46, and the other end of the sixth connection row 46 forms a fast charging negative connection terminal 461.

[0111] The pre-charging relay 21 and the pre-charging resistor 22 are connected in series through a conductive lead, and the pre-charging relay 21 is electrically connected to the positive power connection terminal 411 through the conductive lead, and the pre-charging resistor 22 is electrically connected to the positive power output terminal through the conductive lead.

[0112] Optionally, the distribution box provided in the present application also includes a shunt 47, which is arranged outside or inside the box body 1 and is connected in series to the negative power connection terminal 441. The shunt 47 can be selectively set. The shunt 47 is equipped with a temperature sensor 34 to detect the temperature at that location. In the era of smart cars, the temperature at each point or the operating temperature changes can be monitored through the background big data to identify vehicle risks in advance.

[0113] Optionally, the distribution box provided in the present application also includes a fuse, which is arranged on the outside of the box body 1. Since the current operating conditions of different vehicle models are different, the fuse and the circuit period also need to be matched, and different options are likely to be generated. Therefore, the present application can be applied to more vehicle models to achieve platformization by selecting an external fuse.

[0114] The distribution box provided in the present application includes seven connection terminals and is compatible with mainstream vehicle models on the market. When applied to different vehicle models, each connection terminal can be used selectively, and unnecessary connection terminals can be left unconnected; and voltage detection is performed at each connection terminal, and temperature sensors 34 are respectively provided at the positive power connection terminal 411, the negative power connection terminal 441 and the positive power output terminal 421, which can maximize the safety performance of the distribution box.

[0115] like Figure 4 , Figure 5and 12 As shown, the distribution box provided by the present application, wherein four voltage detection terminals 32 are provided on the circuit board 31, and three voltage detection terminals 32 are provided on the external detection element 33, wherein two of the three voltage detection terminals 32 on the external detection element 33 are connected with temperature sensors 34, wherein one temperature sensor 34 corresponds to detecting the temperature of the positive power connection terminal 411, wherein the other temperature sensor 34 corresponds to detecting the temperature of the positive power output terminal 421, since the temperatures at the positive power connection terminal 411 and the positive power output terminal 421 are roughly the highest temperature positions in the entire power supply path, setting temperature sensors 34 at these two positions can effectively monitor the temperature at the position where the heat is most serious in the power supply route.

[0116] like Figure 1 and Figure 2 As shown, the distribution box provided by the present application, wherein the box body 1 includes a bottom box 11 and a top box, and the bottom box 11 and the top box are detachably connected to form a closed accommodating cavity.

[0117] The bottom box 11 includes a bottom plate 111 , a side wall 112 and a partition plate 113 which are integrally formed by injection molding. The integral molding process is performed by injection molding, which can effectively ensure the sealing performance of the bottom box 11 and the structural strength of each part.

[0118] A portion of the connecting row assembly 4 is buried inside the bottom plate 111 and / or the side wall 112, and a portion of the connecting row assembly 4 extends from the top of the bottom box 11 to the outside thereof to form a connecting terminal; the connecting row assembly 4 is directly fixed together with the bottom box 11 during the injection molding process of the bottom box 11, which can effectively ensure the position maintenance and connection reliability between the connecting row assembly 4 and the bottom box 11, and at the same time can provide a modular bottom box 11. When assembling the distribution box, the installation steps of the connecting row assembly 4 are omitted, the assembly process of the distribution box is simplified, and the assembly efficiency of the distribution box is improved.

[0119] The partition 113 is arranged inside the bottom box 11 and connected to the bottom plate 111 and / or the side wall 112. The inside of the bottom box 11 is divided into a plurality of accommodating spaces by the partition 113, and a part of each electronic component 2 is correspondingly inserted into one accommodating space. In this way, the positioning and assembly of each electronic component 2 can be effectively realized, and the standardized assembly of the distribution box can be further realized.

[0120] The distribution box provided in the present application, wherein the pre-charging relay 21 and the pre-charging resistor 22 are respectively detachably connected to the position of the bottom plate 111 where the connecting row component 4 is not buried through connecting parts, so that the pre-charging relay 21 and the pre-charging resistor 22 are positioned and installed with the box body 1 while avoiding the situation where the pre-charging relay 21 and the pre-charging resistor 22 come into contact with the connecting row component 4 and cause a short circuit; each main relay 23 is respectively detachably connected to the position of the bottom plate 111 where the connecting row component 4 is buried through a connecting part, and the connecting part is a bolt or a connecting part made of other conductive materials, and the circuit conduction between the connecting row component 4 and each main relay 23 is achieved through the connecting part.

[0121] like Fig.13 The present application provides a distribution box, in which a portion of the connection row assembly 4 is exposed to the lower surface of the base plate 111 to improve the heat conduction efficiency of the connection row assembly 4 so that the heat inside the distribution box is transferred to the outside as quickly as possible.

[0122] Specifically, the buried position of the connecting row component 4 corresponding to the lower surface of the bottom plate 111 is hollowed out to expose a portion of the connecting row component 4, or the structure of the mold can be adjusted during the injection molding process, and a punch is set at this position to fit and contact a portion of the connecting row component 4. After the injection molding is completed and the mold is opened, there will be no material covering the connecting row component 4 at the position corresponding to the punch, so that the portion of the connecting row component 4 corresponding to the punch can be exposed.

[0123] The distribution box also includes an insulating film 5 and a thermal pad 6. The insulating film 5 covers the exposed area of ​​the connecting row assembly 4 on the lower surface of the bottom plate 111 to prevent the part of the connecting row assembly 4 exposed on the bottom surface of the box body 1 from contacting with external conductive components and causing a short circuit in the distribution box; the thermal pad 6 is covered on the side of the insulating film 5 away from the box body 1. By providing the thermal pad 6, the heat transfer efficiency can be accelerated, and the heat conduction efficiency from the inside of the distribution box to the outside can be further improved.

[0124] Optionally, the thickness of the insulating film 5 is about 0.2 mm, and the thermal conductivity is about 0.8 W / (m·K); the thermal conductivity of the thermal pad 6 is about 2 W / (m·K), at which time the cost / heat dissipation benefit of the insulating film 5 and the thermal pad 6 is the highest.

[0125] Optionally, the distribution box provided in the present application may be provided with a cooling plate 8 at the bottom thereof. Heat exchange between the cooling plate 8 and the thermal pad 6 can further improve the efficiency of heat conduction from the inside of the distribution box to the outside, thereby achieving rapid cooling of the distribution box.

[0126] Specifically, Fig.13As shown, it mainly reflects the cooling path of the distribution box along the vertical direction. The heat generated by the distribution box is due to the resistance of the electronic components 2 or the connecting row assembly 4. It can be seen from the formula I2 R that the greater the resistance, the greater the heat generated. The main relay 23 has the highest resistance in the distribution box. Generally, the resistance between the two contacts (connected to the connecting row assembly 4) is 0.1mΩ to 0.5mΩ. Therefore, in the cooling design of the distribution box, the contact cooling of the main relay 23 is the design focus. As shown in the figure, the cooling path of the main relay 23 of the present application is from the contact of the main relay 23 to the connecting row assembly 4. The connecting row assembly 4 is coated with an insulating film 5 to achieve insulation and heat conduction, and then the heat is conducted to the cooling plate 8 through the thermal pad 6. The main relay 23 designed in the present application is a 600A relay, plus a cooling plate 8. Through testing, it can be seen that the short-time 900A charging and discharging requirements can be achieved, which meets the 6C charging requirements of most models. Therefore, it can be compatible with the charging rate requirements that may increase in the future, and realize platform design.

[0127] like Figure 1 and Figure 2 As shown, the power distribution box provided by the present application further includes a battery management unit 7 (Battery Management System, BMS), the battery management unit 7 includes a circuit component 72 and a shell 71, the shell 71 can be detachably installed on the top surface of the box body 1, the shell 71 and the top surface of the box body 1 enclose a mounting cavity, the circuit component 72 is arranged inside the mounting cavity, the shell 71 can provide protection for the circuit component 72, and can also play a certain role in electrical isolation. Integrating the battery management unit 7 into the power distribution box in this way can simplify the structure and assembly steps of the existing power distribution box and the battery management unit 7, which is conducive to reducing the overall volume and realizing miniaturization, so that the overall size of the power distribution box is only 340mm*165mm*110mm.

[0128] The main functions of the battery management unit 7 include voltage monitoring, current monitoring, temperature monitoring, insulation monitoring, electronic component 2 status monitoring, etc., to improve the electrical safety of the distribution box.

[0129] The present application also provides a method for assembling a power distribution box, wherein the method for assembling a power distribution box is used to assemble the power distribution box as described above, and the method for assembling a power distribution box includes:

[0130] Set box body 1;

[0131] The electronic component 2 is arranged inside the box body 1, and a part of the electronic component 2 and the first part of the lead member 3 are connected to the box body 1 through a connector;

[0132] Press the electronic components 2 tightly against the inside of the box, turn over the box body 1, connect another part of the electronic components 2 to the box body 1 through the connector, and turn over the box body 1 again;

[0133] The second portion of the lead member 3 is provided, the second portion of the lead member 3 is connected to the first portion of the lead member 3 , and each electronic component 2 is connected to the second portion of the lead member 3 .

[0134] The assembly method of the distribution box provided in the embodiment of the present application adopts the lead member 3 to realize the structural connection and electrical connection of each electronic component 2. The lead member 3 replaces the flexible wiring harness, and the lead member 3 can complete the connection relationship with each electronic component 2 through the assembly production line, thereby realizing automated assembly and effectively improving assembly efficiency.

[0135] The assembly method of the power distribution box provided in the present application, wherein the setting of the box body 1 specifically includes:

[0136] The connecting row assembly 4 is integrally formed with the bottom box 11 of the box body 1 by injection molding. The connecting row assembly 4 is directly fixed to the bottom box 11 during the injection molding process of the bottom box 11, which can effectively ensure the position maintenance and connection reliability between the connecting row assembly 4 and the bottom box 11, and at the same time can provide a modular bottom box 11. When assembling the distribution box, the installation steps of the connecting row assembly 4 are omitted, the assembly process of the distribution box is simplified, and the assembly efficiency of the distribution box is improved.

[0137] The box body 1 includes an integrally formed bottom plate 111 , a side wall 112 and a partition plate 113 , which are integrally formed by injection molding, and can effectively ensure the sealing performance of the bottom box 11 and the structural strength of each part.

[0138] The partition 113 divides the interior of the box body 1 into a plurality of accommodating spaces, which can effectively realize the positioning and assembly of each electronic component 2 and further realize the standardized assembly of the distribution box.

[0139] The assembly method of the power distribution box provided in the present application, wherein the electronic component 2 is arranged inside the box body 1, and a part of the electronic component 2 and the first part of the lead member 3 are connected to the box body 1 through a connector, specifically comprising:

[0140] The pre-charging relay 21, the pre-charging resistor 22 and a plurality of main relays 23 are arranged inside the box body 1, and at least a portion of each electronic component 2 is correspondingly inserted into a receiving space; the positioning and assembly of each electronic component 2 can be effectively realized, and the standardized assembly of the distribution box can be further realized.

[0141] An external detection element 33 is provided on the lead member 3; the external detection element 33 is arranged above the bottom box 11, and the pre-charge relay 21, the pre-charge resistor 22 and the external detection element 33 are detachably connected to the box body 1 through a connector, so as to realize the positioning connection between the pre-charge relay 21, the pre-charge resistor 22 and the external detection element 33 and the box body 1.

[0142] The assembly method of the power distribution box provided in the present application, wherein the electronic component 2 is pressed tightly against the inside of the box body 1, the box body 1 is turned over, another part of the electronic component 2 is connected to the box body 1 through a connector, and the box body 1 is turned over again, specifically comprising:

[0143] The main relays 23 are compressed by the compression tool;

[0144] Turn the box body 1 180° so that the bottom of the box body 1 faces upward, and press each main relay 23 by pressing, so that each main relay 23 always keeps in contact with the bottom plate 111 of the bottom box 11, so as to ensure that subsequent connection is convenient and effective;

[0145] Each main relay 23 is detachably connected to the box body 1 through a connecting piece;

[0146] The box body 1 is turned over 180 degrees to restore the box body to a state where the opening faces upward.

[0147] The assembly method of the distribution box provided in the present application, wherein the second part of the lead member 3 is provided, the second part of the lead member 3 is connected to the first part of the lead member 3, and each electronic component 2 is connected to the second part of the lead member 3, specifically comprising:

[0148] A circuit board 31 is arranged above each electronic component 2;

[0149] The external detection element 33 is connected and electrically connected to the circuit board 31; the circuit board 31 is indirectly connected to the bottom shell through the external detection element 33; it should be noted that a connecting member can also be provided to connect the circuit board 31 to the bottom box 11 or the top box to improve the connection reliability between the circuit board 31 and the box body 1.

[0150] Each electronic component 2 is fixedly welded and electrically connected to the circuit board 31 to complete the conduction of the distribution box circuit.

[0151] The present application provides a method for assembling a power distribution box, wherein the method for assembling a power distribution box further comprises:

[0152] A top box is arranged above the bottom box 11, and the top box is detachably connected to the bottom box 11, so as to achieve sealing of the power distribution box and ensure electrical safety during its use.

[0153] A battery management unit 7 is arranged above the top box. The main functions of the battery management unit 7 include voltage monitoring, current monitoring, temperature monitoring, insulation monitoring, electronic component 2 status monitoring, etc., to improve the electrical safety of the distribution box.

[0154] The battery management unit 7 is detachably connected to the upper surface of the top box, and the battery management unit 7 is integrated with the distribution box, which can simplify the structure and assembly steps of the two, and is conducive to reducing the overall volume of the two and achieving miniaturization.

[0155] In the distribution box and the assembly method of the distribution box provided in the present application, laser welding is used for welding. Selecting welding can realize automated assembly production and can greatly improve production efficiency.

[0156] The present application also provides a powertrain, wherein the powertrain includes the distribution box as described above.

[0157] The powertrain provided in the embodiment of the present application has a distribution box in which a lead member 3 is used to achieve structural and electrical connection of each electronic component 2. The lead member 3 replaces the flexible wiring harness, and the lead member 3 can be connected to each electronic component 2 through an assembly production line, thereby realizing automated assembly and effectively improving assembly efficiency.

[0158] The present application also provides a vehicle, wherein the vehicle includes the distribution box or powertrain as described above.

[0159] The vehicle provided in the embodiment of the present application has a distribution box that uses a lead member 3 to achieve structural and electrical connections of each electronic component 2. The lead member 3 replaces the flexible wiring harness, and the lead member 3 can complete the connection relationship with each electronic component 2 through an assembly production line, thereby realizing automated assembly and effectively improving assembly efficiency.

Claims

1. A distribution box, characterized in that: The power distribution box comprises: Box body; A plurality of electronic components are detachably installed inside the box body, and a pin is provided on the top of each of the electronic components; A lead member is arranged above each of the electronic components, a conductive lead is embedded in the lead member, a pin of each of the electronic components is fixedly connected to the lead member, and the pin of each of the electronic components is electrically connected to the conductive lead.

2. The power distribution box according to claim 1, characterized in that: The distribution box also includes a connection bar assembly, a portion of which is fixedly connected to the box body, and a portion of which extends to the outside of the box body to form a connection terminal, and at least part of the electronic components are electrically connected to the connection bar assembly.

3. The power distribution box according to claim 2, characterized in that: The electronic components include a pre-charge relay, a pre-charge resistor and a plurality of main relays; The pre-charging relay and the pre-charging resistor are both connected to the lead member; Each of the main relays is connected to the lead member and the connection bar assembly respectively.

4. The power distribution box according to claim 3, characterized in that: The lead structure includes a circuit board, and a hole structure is opened on the circuit board corresponding to each of the electronic components. The conductive lead is buried in a position on the circuit board where the hole structure is not opened. A lead terminal is protruded on the hole wall of the hole structure, and the lead terminal is electrically connected to the conductive lead. Each of the electronic components is fixedly connected and electrically connected to the lead terminal at the corresponding hole structure.

5. The power distribution box according to claim 4, characterized in that: A plurality of voltage detection terminals are connected to the periphery of the circuit board, each of the voltage detection terminals is electrically connected to one of the connection terminals, and the voltage detection terminals are configured to detect the voltage at the corresponding connection terminal.

6. The power distribution box according to claim 5, characterized in that: The voltage detection terminal is fixedly connected to the circuit board; And / or, a connection port is provided on the circuit board, and the lead member further comprises an external detection element, the external detection element is fixedly connected to the connection port and connected to the box body, and the external detection element is provided with at least one voltage detection terminal.

7. The power distribution box according to claim 5 or 6, characterized in that: At least some of the voltage detection terminals are connected with temperature sensors.

8. The power distribution box according to claim 4, characterized in that: Positioning holes are provided on the circuit board, and positioning pieces are provided on the tops of at least some of the electronic components, and the positioning pieces are plugged into the positioning holes for positioning.

9. The power distribution box according to claim 3, characterized in that: The pins of the electronic components are arranged vertically, the power distribution box further comprises an adapter, the adapter is formed with a first connection surface facing upwards, the pins are plugged and fixed to the adapter and are electrically connected to the first connection surface, and the first connection surface is welded and fixed to the lead member; And / or, the pin is horizontally arranged and has a second connection surface facing upward, and the second connection surface is welded and fixed to the lead member.

10. The power distribution box according to claim 9, characterized in that: The pre-charging relay and the pre-charging resistor are respectively connected and electrically connected to the lead component through the adapter; each main relay is directly connected and electrically connected to the lead component.

11. The power distribution box according to claim 3, characterized in that: Each of the main relays includes a main positive relay, a main negative relay, a fast charge positive relay, a fast charge negative relay and a boost relay; The connecting bar assembly includes a first connecting bar, a second connecting bar, a third connecting bar, a fourth connecting bar, a fifth connecting bar and a sixth connecting bar which are independent of each other; The connection terminals include a positive power connection terminal, a negative power connection terminal, a positive power output terminal, a negative power output terminal, a fast charge positive connection terminal, a fast charge negative connection terminal and a boost positive connection terminal; One end of the first connection row forms the positive power connection terminal, and the other end of the first connection row is respectively connected to the main positive relay and the fast charging positive relay, the main positive relay and the fast charging positive relay are arranged in parallel, and are both connected to the second connection row, one end of the second connection row forms the positive power output terminal, and the other end of the second connection row forms the fast charging positive connection terminal, the boost relay is respectively connected to one end of the second connection row and the third connection row, and the other end of the third connection row forms the boost positive connection terminal; One end of the fourth connection row forms the negative electrode of the power supply to connect electrons, the other end of the fourth connection row is connected to the main negative relay, the main negative relay is connected to one end of the fifth connection row, the other end of the fifth connection row forms the negative electrode output terminal of the power supply, the fast charging negative relay is respectively connected to one end of the fourth connection row and the sixth connection row, and the other end of the sixth connection row forms the fast charging negative electrode connection terminal.

12. The power distribution box according to claim 11, characterized in that: The pre-charging relay and the pre-charging resistor are connected in series through the conductive lead, and the pre-charging relay is electrically connected to the positive connection terminal of the power supply through the conductive lead, and the pre-charging resistor is electrically connected to the positive output terminal of the power supply through the conductive lead.

13. The power distribution box according to claim 11 or 12, characterized in that: The power positive connection terminal and the power positive output terminal are connected with a temperature sensor.

14. The power distribution box according to claim 3, characterized in that: The box body comprises a bottom box and a top box, and the bottom box and the top box are detachably connected; The bottom box includes a bottom plate, side walls and partitions, a portion of the connection row assembly is buried inside the bottom plate and / or the side walls, and a portion of the connection row assembly extends from the top of the bottom box to the outside thereof to form the connection terminal; the partition is arranged inside the bottom box and connected to the bottom plate and / or the side walls, the interior of the bottom box is divided by the partition to form a plurality of accommodating spaces, and a portion of each of the electronic components is correspondingly inserted in one of the accommodating spaces.

15. The power distribution box according to claim 14, characterized in that: The pre-charging relay and the pre-charging resistor are detachably connected to the position of the bottom plate where the connecting row assembly is not buried through connecting parts; each main relay is detachably connected to the position of the bottom plate where the connecting row assembly is buried through connecting parts.

16. The power distribution box according to claim 14 or 15, characterized in that: A portion of the connection row assembly is exposed on the lower surface of the bottom plate; The power distribution box further comprises an insulating film and a thermal pad, wherein the insulating film covers the exposed area of ​​the connection row assembly on the lower surface of the bottom plate, and the thermal pad is disposed on a side of the insulating film away from the box body.

17. The power distribution box according to claim 1, characterized in that: The distribution box also includes a battery management unit, which includes a circuit component and a shell. The shell can be detachably installed on the top surface of the box body. The shell and the top surface of the box body form an installation cavity, and the circuit component is arranged inside the installation cavity.

18. A method for assembling a distribution box, characterized in that: The method for assembling the power distribution box is used to assemble the power distribution box according to any one of claims 1 to 17, and the method for assembling the power distribution box comprises: Set up the box body; Placing electronic components inside the box body, and connecting a portion of the electronic components and the first portion of the lead member to the box body through a connector; Press the electronic components tightly inside the box body, turn over the box body, connect another part of the electronic components to the box body through a connector, and turn over the box body again; A second portion of the lead member is provided, the second portion of the lead member is connected to the first portion of the lead member, and each of the electronic components is connected to the second portion of the lead member.

19. The method for assembling a power distribution box according to claim 18, characterized in that: The setting box body comprises: The connecting row assembly is formed with the bottom box of the box body by injection molding. The box body includes an integrally formed bottom plate, side walls and partitions. The partitions divide the interior of the box body into a plurality of accommodating spaces.

20. The method for assembling a power distribution box according to claim 19, characterized in that: The electronic components are arranged inside the box body, and a part of the electronic components and the first part of the lead member are connected to the box body through a connector, including: The pre-charging relay, the pre-charging resistor and the plurality of main relays are arranged inside the box body, and at least a part of each of the electronic components is correspondingly inserted into one of the accommodating spaces; An external detection element is provided for the lead member; The pre-charging relay, the pre-charging resistor and the external detection element are detachably connected to the box body through the connecting piece.

21. The method for assembling a power distribution box according to claim 20, characterized in that: Pressing the electronic components tightly inside the box body, turning over the box body, connecting another part of the electronic components to the box body through a connector, and turning over the box body again, comprises: Compressing each of the main relays by means of a pressing tool; Turn the box body 180° so that the bottom of the box body faces upward; Each of the main relays is detachably connected to the box body through the connecting piece; The box body is turned over 180°.

22. The method for assembling a power distribution box according to claim 21, characterized in that: Providing a second portion of the lead member, connecting the second portion of the lead member to the first portion of the lead member, and connecting each of the electronic components to the second portion of the lead member, comprising: Arranging a circuit board above each of the electronic components; Connecting and electrically connecting the external detection element to the circuit board; Each of the electronic components is electrically connected to the circuit board.

23. The method for assembling a distribution box according to any one of claims 19 to 22, characterized in that: The assembly method of the power distribution box also includes: A top box is arranged above the bottom box, and the top box is detachably connected to the bottom box; A battery management unit is arranged above the top box, and the battery management unit is detachably connected to the upper surface of the top box.

24. A powertrain, characterized in that: The power assembly includes a distribution box as described in any one of claims 1 to 17 or a distribution box assembled by the method for assembling a distribution box as described in any one of claims 18 to 23.

25. A vehicle, characterized in that: The vehicle comprises a distribution box as described in any one of claims 1 to 17, a distribution box assembled by the method for assembling a distribution box as described in any one of claims 18 to 23, or a powertrain as described in claim 23.

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