An electrical connection structure and assembly method for a high-voltage distribution box of an electric vehicle

Abstract

The present invention relates to the technical field of high-voltage power distribution, and in particular to an electric connection structure and an assembly method of a high-voltage distribution box of an electric vehicle, comprising a wiring harness structure and a distribution box (1); the wiring harness structure comprises a sheet-type pin structure; the distribution box (1) is provided with a socket structure (2); the sheet-type pin structure is connected to the socket structure (2); the distribution box is provided with a socket structure, and the wiring harness structure is provided with a sheet-type pin structure; the sheet-type pin structure is plugged into the socket structure to achieve electrical connection between the wiring harness structure and the distribution box; the present application simplifies the electrical connection structure, reduces the material used, and significantly reduces the overall cost; at the same time, when the present application is installed, the staff only needs to insert the wiring harness structure into the distribution box and tighten the connecting bolts to complete the electrical connection between the wiring harness structure and the distribution box; the present application greatly simplifies the electrical connection operation and improves the work efficiency.

Description

Technical Field

[0001] The present invention relates to the technical field of high-voltage power distribution, and in particular to an electrical connection structure and an assembly method of a high-voltage distribution box for an electric vehicle. Background Art

[0002] High-voltage power distribution is one of the essential functions of electric vehicles. It mainly realizes the redistribution of electric energy to meet the working requirements of various high-voltage components and improve the customer driving experience. The CDU (Charge Distributor Unit) is a system solution that integrates the on-board charger (OBC), on-board DC / DC converter (DC / DC Converter) and high-voltage power distribution unit (PDU). The BDU (Battery Distributor Unit) is responsible for the power distribution, protection and management of the battery pack.

[0003] At present, electric vehicles on the market mainly use a combination of CDU and BDU (battery internal distribution part) to realize the power distribution function. A small number of electric vehicles use a combination of independent PDU (high-voltage distribution box) and BDU or a multi-in-one form combining multiple functional modules to realize the power distribution function. Regardless of the form, electrical connection technology is an indispensable requirement in the power distribution part. The technology for electric vehicle power distribution connection on the market is mainly quick plug-in or through-hole connector. Quick plug-in products are relatively expensive and occupy a large operating space, which is not conducive to the utilization of vehicle space. Through-hole connectors also require large assembly tools, which is not conducive to the utilization of vehicle space. In addition, the disassembly and assembly process requires opening the outer cover of the box, which makes the operation complicated and takes up more working hours. The assembly process has high labor costs.

[0004] After searching, the applicant found that the Chinese patent document with publication number 216563428U disclosed a power battery high-voltage distribution unit and its electrical connector on May 17, 2022. The electrical connector includes an insulator; a conductive column is fixedly provided on the insulator, and the conductive column passes through the insulator. One end of the conductive column is used to connect to the conductive column of other electrical connectors, and the other end is used to connect to the charger or battery or load; a mounting part is fixedly provided on the insulator, and the mounting part is used to fix the insulator in the box of the power battery high-voltage distribution unit; this device also cannot solve the above technical problems.

[0005] Therefore, in order to improve or solve at least one of the above problems, it is necessary to provide an electric vehicle high-voltage distribution box electrical connection structure and assembly method that can reduce the cost of the electrical connection structure and simplify the electrical connection operation of the wiring harness in the high-voltage distribution box. Summary of the Invention

[0006] The object of the present invention is to provide an electric vehicle high-voltage distribution box electrical connection structure and an assembly method thereof, which can reduce the cost of the electrical connection structure and simplify the electrical connection operation of the wiring harness in the high-voltage distribution box.

[0007] In order to solve the above technical problems, the technical solution adopted by the present invention is: an electrical connection structure of a high-voltage distribution box of an electric vehicle, including a wiring harness structure and a distribution box body; the wiring harness structure includes a sheet-type pin structure; a socket structure is provided in the distribution box body; the sheet-type pin structure is connected to the socket structure.

[0008] The wiring harness structure includes a positive wiring harness and a negative wiring harness; the sheet pin structure includes a positive pin and a negative pin; the jack structure includes a positive jack and a negative jack; the positive jack and the negative jack are both connected to a copper bus; the positive pin is arranged on the positive wiring harness, and the positive pin is connected to the positive jack; the negative pin is arranged on the negative wiring harness, and the negative pin is connected to the negative jack.

[0009] A guide frame is provided in the distribution box body; the distribution box body includes a side wall; a wire harness mounting hole is provided on the side wall; the guide frame is provided on one side of the wire harness mounting hole; a jack mounting groove and a guide groove are respectively provided on the guide frame; the positive jack and the negative jack are both provided in the jack mounting groove; the positive wiring harness and the negative wiring harness are both provided in the guide groove.

[0010] The positive wiring harness is connected to a wiring harness fixing frame; the wiring harness fixing frame is connected to the negative wiring harness; a connecting sleeve is provided on the distribution box; the connecting sleeve is communicated with the wiring harness mounting hole, and the wiring harness fixing frame is connected to the connecting sleeve.

[0011] The connecting sleeve is provided with a slot; the slot includes a convex section; the wire harness fixing frame is provided with a concave section; the wire harness fixing frame is arranged in the slot, and the concave section is engaged with the convex section.

[0012] Bolt holes are provided on the raised section and the recessed section; connecting bolts are provided in the bolt holes.

[0013] The positive wiring harness and the negative wiring harness both include a first shaft segment and a second shaft segment; a conductive copper foil is connected to the second shaft segment; a shielding ring is connected to the conductive copper foil; the slot includes a first slot and a second slot; the shielding ring is tightly pressed against the inner wall of the second slot.

[0014] A sealing rubber ring is provided on the first shaft section; the sealing rubber ring is arranged on one side of the wiring harness fixing frame; and the sealing rubber ring is tightly pressed against the inner wall of the first slot.

[0015] The wiring harness fixing frame includes an upper fixing frame and a lower fixing frame; the wiring harness structure is connected between the upper fixing frame and the lower fixing frame; the wiring harness fixing frame is respectively provided with a positive wiring harness hole and a negative wiring harness hole; the positive wiring harness is arranged in the positive wiring harness hole; the negative wiring harness is arranged in the negative wiring harness hole; a support is provided at the bottom of the guide frame; the support is connected to the distribution box.

[0016] An assembly method for the electric connection structure of the high-voltage distribution box of an electric vehicle, the assembly method comprising the following steps:

[0017] S1: Insert the harness fixing bracket into the slot of the connecting sleeve; insert the positive pin into the positive jack; insert the negative pin into the negative jack;

[0018] S2: Connect the connecting bolts in the bolt holes.

[0019] The beneficial effects of this application are:

[0020] The present application provides a socket structure for connecting the copper busbar in the distribution box, and a sheet-type pin structure is provided on the wiring harness structure; the sheet-type pin structure and the socket structure are plugged into each other to realize the electrical connection between the wiring harness structure and the high-voltage distribution box; the present application eliminates the shell of the existing quick-plug structure itself, simplifies the electrical connection structure, reduces the material used, and significantly reduces the overall cost.

[0021] The electrical connection structure of the high-voltage distribution box of an electric vehicle of the present application, when being installed, the staff only needs to insert the wiring harness structure into the distribution box body and lock the connecting bolts in two actions to complete the electrical connection between the wiring harness structure and the high-voltage distribution box; the present application greatly simplifies the electrical connection operation and improves work efficiency; compared with the existing through-hole connector, there is no need to disassemble the upper end cover of the box body and lock the fixing bolts of the center line nose of the conventional through-hole connector, which is convenient to operate, with short working hours and low overall cost; and compared with the existing plug-in connector and through-hole connector, the space occupied by the assembly operation is significantly reduced. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The specific embodiments of the present invention are further described in detail below with reference to the accompanying drawings, in which:

[0023] Figure 1 This is a structural diagram of the electrical connection structure of the high-voltage distribution box of this electric vehicle.

[0024] Figure 2 This is a schematic diagram of the wiring harness structure of the electrical connection structure of the high-voltage distribution box of this electric vehicle.

[0025] Figure 3 This is a structural schematic diagram of the wire harness fixing frame of the electrical connection structure of the high-voltage distribution box of this electric vehicle.

[0026] Figure 4 This is a structural schematic diagram of the connecting sleeve of the electrical connection structure of the high-voltage distribution box of the electric vehicle.

[0027] Figure 5 This is a cross-sectional view of the electrical connection structure of the high-voltage distribution box of this electric vehicle.

[0028] The marks in the above figure are:

[0029] The markings in the figure are: 1, distribution box body, 101, side wall, 102, wiring harness installation hole,

[0030] 2. Jack structure,

[0031] 3. Positive wiring harness, 301, positive pin,

[0032] 4. Negative wiring harness, 401, negative pin,

[0033] 5. Positive jack,

[0034] 6. Negative jack,

[0035] 7. Copper busbar,

[0036] 8. Guide frame, 801. Jack mounting slot, 802. Guide slot, 803. Support,

[0037] 9. Wire harness fixing frame, 901. Concave section, 902. Upper fixing frame, 903. Lower fixing frame, 904. Positive wire harness hole, 905. Negative wire harness hole,

[0038] 10. Connecting sleeve,

[0039] 11. Slot, 111. Raised section, 112. Bolt hole, 113. Connecting bolt, 114. First slot, 115. Second slot,

[0040] 12. First shaft section, 121. Sealing rubber ring,

[0041] 13. Second shaft segment, 131. Conductive copper foil, 132. Shielding ring. DETAILED DESCRIPTION

[0042] The following is a further detailed description of the specific implementation methods of the present invention through the description of embodiments with reference to the accompanying drawings, with the aim of helping those skilled in the art to have a more complete, accurate and in-depth understanding of the inventive concept and technical solution of the present invention and to facilitate their implementation.

[0043] Figure 1The electrical connection structure of a high-voltage distribution box of an electric vehicle shown in the figure includes a wiring harness structure and a distribution box body 1; the wiring harness structure includes a sheet-type pin structure; a socket structure 2 is provided in the distribution box body 1; the sheet-type pin structure is connected to the socket structure 2.

[0044] A socket structure 2 is provided in the distribution box 1, and a sheet pin structure is provided on the wiring harness structure; the sheet pin structure is connected to the socket structure 2 to realize the electrical connection between the wiring harness structure and the distribution box 1; the shell of the existing quick plug-in structure itself is eliminated, and the present application simplifies the electrical connection structure, reduces the material used, and significantly reduces the overall cost; at the same time, when installing the present application, the staff only needs to insert the wiring harness structure into the distribution box 1 and tighten the connecting bolts to complete the electrical connection between the wiring harness structure and the distribution box 1; the present application greatly simplifies the electrical connection operation and improves work efficiency.

[0045] The wiring harness structure includes a positive wiring harness 3 and a negative wiring harness 4; the sheet pin structure includes a positive pin 301 and a negative pin 401; the socket structure 2 includes a positive socket 5 and a negative socket 6; the positive socket 5 and the negative socket 6 are both connected to a copper bus 7; the positive pin 301 is arranged on the positive wiring harness 3, and the positive pin 301 is connected to the positive socket 5; the negative pin 401 is arranged on the negative wiring harness 4, and the negative pin 401 is connected to the negative socket 6.

[0046] The positive pin 301 and the negative pin 401 are both sheet-type pin structures; the positive pin 301 is connected to the end of the positive wiring harness 3; the negative pin 401 is connected to the end of the negative wiring harness 4; the sheet-type pin structure is directly connected to the wiring harness structure in the distribution box 1, reducing the intermediate transition structure (solid body and cold pressing) part and reducing the use of copper materials; sheet-type sockets are provided on the positive jack 5 and the negative jack 6, reducing the process difficulty and reducing the use of copper materials; the positive pin 301 and the negative pin 401 are plugged into the sheet-type sockets; the positive jack 5 and the negative jack 6 are both hard-connected to the copper bus 7, and the connection points can be welded or further decomposed for bolts or other forms of connection.

[0047] A guide frame 8 is provided in the distribution box body 1; the distribution box body 1 includes a side wall 101; a wiring harness mounting hole 102 is provided on the side wall 101; the guide frame 8 is arranged on one side of the wiring harness mounting hole 102; a jack mounting groove 801 and a guide groove 802 are respectively provided on the guide frame 8; the positive jack 5 and the negative jack 6 are both arranged in the jack mounting groove 801; the positive wiring harness 3 and the negative wiring harness 4 are both arranged in the guide groove 802.

[0048] The guide frame 8 is fixedly connected to the distribution box body 1; two guide frames 8 are provided in the distribution box body 1, and the positive jack 5 and the negative jack 6 are respectively connected to the guide frames 8; the positive jack 5 and the negative jack 6 are both fixedly connected to the jack mounting groove 801; two wiring harness mounting holes 102 are respectively provided on the side wall 101; the positive wiring harness 3 and the negative wiring harness 4 extend from the wiring harness mounting holes 102 respectively, and pass through the guide groove 802 to be plugged into the jack structure 2; the guide groove 802 can provide a limit for the positive wiring harness 3 and the negative wiring harness 4.

[0049] The positive wiring harness 3 is connected to a wiring harness fixing frame 9 ; the wiring harness fixing frame 9 is connected to the negative wiring harness 4 ; a connecting sleeve 10 is provided on the distribution box 1 ; the connecting sleeve 10 is communicated with the wiring harness mounting hole 102 , and the wiring harness fixing frame 9 is connected to the connecting sleeve 10 .

[0050] The positive wiring harness 3 and the negative wiring harness 4 are both fixedly connected to the wiring harness fixing frame 9; the connecting sleeve 10 is a hollow tube structure; the wiring harness fixing frame 9 is inserted into the connecting sleeve 10, which can realize effective guidance of the wiring harness structure during installation, and at the same time can realize stable connection of the wiring harness structure due to the distribution box 1.

[0051] The connecting sleeve 10 is provided with a slot 11 ; the slot 11 includes a raised section 111 ; the harness fixing frame 9 is provided with a recessed section 901 ; the harness fixing frame 9 is arranged in the slot 11 , and the recessed section 901 is engaged with the raised section 111 .

[0052] The raised section 111 is arranged in the middle of the connecting sleeve 10; the raised section 111 extends into the inside of the card slot 11; the concave section 901 is arranged in the middle of the wire harness fixing frame 9; a groove is provided on the concave section 901; when the wire harness fixing frame 9 is inserted into the card slot 11, the concave section 901 is engaged in the groove, thereby realizing effective limiting of the wire harness fixing frame 9 in the connecting sleeve 10, and ensuring a stable connection between the wire harness fixing frame 9 and the connecting sleeve 10.

[0053] Bolt holes 112 are provided on the raised section 111 and the recessed section 901 ; connecting bolts 113 are provided in the bolt holes 112 .

[0054] By connecting the connecting bolt 113 in the bolt hole 112, the wiring harness fixing frame 9 and the connecting sleeve 10 can be stably connected; the bolt hole 112 on the raised section 111 can be a waist-shaped hole, which can absorb the installation tolerance of the wiring harness structure and ensure that the contact-to-contact meets the current carrying capacity and meets the requirements.

[0055] Both the positive wiring harness 3 and the negative wiring harness 4 include a first shaft segment 12 and a second shaft segment 13; a conductive copper foil 131 is connected to the second shaft segment 13; a shielding ring 132 is connected to the conductive copper foil 131; the slot 11 includes a first slot 114 and a second slot 115; the shielding ring 132 is tightly pressed against the inner wall of the second slot 115.

[0056] The first shaft section 12 and the second shaft section 13 are an integral structure; the shaft diameter of the second shaft section 13 is smaller than that of the first shaft section 12; the conductive copper foil 131 is sleeved on the second shaft section 13 and is arranged at the end of the second shaft section 13 close to the second shaft section 13; the shielding ring 132 is sleeved on the conductive copper foil 131; the wiring harness structure, the conductive copper foil 131 and the shielding ring 132 form a contact shielding chain with the connecting sleeve 10; the size of the second card slot 115 is smaller than the first card slot 114; when the wiring harness fixing frame 9 is inserted into the card slot 11, the first shaft section 12 is arranged in the first card slot 114, and the first shaft section 12 and the end of the second card slot 115 are tightly pressed against each other, thereby avoiding excessive insertion force causing the wiring harness structure to bend and deform, affecting the introduction of the sheet-type pin structure or causing damage to the spring inside the jack structure 2, affecting the electrical contact effect.

[0057] A sealing rubber ring 121 is provided on the first shaft section 12 ; the sealing rubber ring 121 is provided on one side of the wiring harness fixing frame 9 ; the sealing rubber ring 121 is tightly pressed against the inner wall of the first slot 114 .

[0058] The sealing rubber ring 121 is sleeved on the first shaft segment 12, and the sealing rubber ring 121 is arranged at the end of the first shaft segment 12 close to the second shaft segment 13; the wiring harness structure, the sealing rubber ring 121 and the connecting sleeve 10 form a contact sealing chain; which can effectively prevent external dust or other impurities from entering the distribution box 1.

[0059] The wiring harness fixing frame 9 includes an upper fixing frame 902 and a lower fixing frame 903; the upper fixing frame 902 and the lower fixing frame 903 are connected by bolts; the wiring harness structure is connected between the upper fixing frame 902 and the lower fixing frame 903; the wiring harness fixing frame 9 is respectively provided with a positive wiring harness hole 904 and a negative wiring harness hole 905; the positive wiring harness 3 is arranged in the positive wiring harness hole 904; the negative wiring harness 4 is arranged in the negative wiring harness hole 905; a support 803 is provided at the bottom of the guide frame 8; the support 803 is connected to the distribution box 1.

[0060] An assembly method for an electric connection structure of a high-voltage distribution box of an electric vehicle, the assembly method comprising the following steps:

[0061] S1: Insert the harness fixing frame 9 into the slot 11 of the connecting sleeve 10; insert the positive electrode pin 301 into the positive electrode jack 5; and insert the negative electrode pin 401 into the negative electrode jack 6;

[0062] S2: Connect the connecting bolt 113 into the bolt hole 112 .

[0063] In S1, the on-site personnel directly insert the positive pin 301 and the negative pin 401 into the corresponding positive jack 5 and negative jack 6 of the distribution box 1 to form a contact pair; the positive jack 5 and the negative jack 6 are welded together with the copper bus 7; during the insertion process, the raised section 111 is provided in the connecting sleeve 10 and the concave section 901 is provided in the middle of the wiring harness fixing frame 9 to form a wiring harness assembly positioning fit; the guide frame 8 is provided in the distribution box 1 to guide the movement path of the positive pin 301 and the negative pin 401 during the wiring harness assembly process to ensure that the wiring harness pins are assembled in place;

[0064] In S2, the connecting bolt 113 is connected to the bolt hole 112 to form a bolt connection, fix the wiring harness structure and the distribution box 1, avoid the wiring harness structure from retreating outward and causing poor contact of the contact pair, and at the same time perform secondary positioning of the contact pair, wherein the guide frame 8 is assembled with the distribution box 1 through the support 803; after the insertion is completed, the positive wiring harness 3, the conductive copper foil 131, the shielding ring 132 and the distribution box 1, and the negative wiring harness 4, the conductive copper foil 131, the shielding ring 132 and the distribution box 1 respectively form a contact shielding chain; after the insertion is completed, the positive wiring harness 3, the sealing rubber ring 121 and the distribution box 1, and the negative wiring harness 4, the sealing rubber ring 121 and the distribution box 1 respectively form a contact sealing chain, so as to ensure that the conductive contact, shielding contact and sealed contact of the product with the distribution box 1 meet the product use requirements.

[0065] The specific workflow of the present invention is as follows:

[0066] S1: Insert the harness fixing frame 9 into the slot 11 of the connecting sleeve 10; insert the positive electrode pin 301 into the positive electrode jack 5; and insert the negative electrode pin 401 into the negative electrode jack 6;

[0067] S2: Connect the connecting bolt 113 into the bolt hole 112 .

[0068] The present invention has been described above with reference to the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-described method. Any non-substantial improvements made using the method concepts and technical solutions of the present invention, or any direct application of the above-described concepts and technical solutions to other situations without modification, fall within the scope of protection of the present invention.

Claims

1. An electric connection structure for a high voltage distribution box of an electric vehicle, characterized in that: It comprises a wiring harness structure and a power distribution box (1); the wiring harness structure comprises a sheet-type pin structure; a socket structure (2) is provided in the power distribution box (1); the sheet-type pin structure is connected to the socket structure (2).

2. An electric vehicle high voltage distribution box electrical connection structure according to claim 1, characterized in that: The wiring harness structure comprises a positive wiring harness (3) and a negative wiring harness (4); the sheet-type pin structure comprises a positive pin (301) and a negative pin (401); the socket structure (2) comprises a positive socket (5) and a negative socket (6); the positive socket (5) and the negative socket (6) are both connected to a copper busbar (7); the positive pin (301) is arranged on the positive wiring harness (3), and the positive pin (301) is connected to the positive socket (5); the negative pin (401) is arranged on the negative wiring harness (4), and the negative pin (401) is connected to the negative socket (6).

3. An electric vehicle high voltage distribution box electrical connection structure according to claim 2, characterized in that: The distribution box (1) is provided with a guide frame (8); the distribution box (1) comprises a side wall (101); the side wall (101) is provided with a wiring harness mounting hole (102); the guide frame (8) is arranged on one side of the wiring harness mounting hole (102); the guide frame (8) is provided with a socket mounting groove (801) and a guide groove (802); the positive electrode socket (5) and the negative electrode socket (6) are both arranged in the socket mounting groove (801); the positive electrode wiring harness (3) and the negative electrode wiring harness (4) are both arranged in the guide groove (802).

4. An electric vehicle high voltage distribution box electrical connection structure according to claim 3, characterized in that: The positive wiring harness (3) is connected to a wiring harness fixing frame (9); the wiring harness fixing frame (9) is connected to the negative wiring harness (4); a connecting sleeve (10) is provided on the power distribution box (1); the connecting sleeve (10) is connected to the wiring harness mounting hole (102), and the wiring harness fixing frame (9) is connected to the connecting sleeve (10).

5. An electric vehicle high voltage distribution box electrical connection structure according to claim 4, characterized in that: The connecting sleeve (10) is provided with a slot (11); the slot (11) includes a raised section (111); the wire harness fixing frame (9) is provided with a recessed section (901); the wire harness fixing frame (9) is arranged in the slot (11), and the recessed section (901) is engaged with the raised section (111).

6. An electric connection structure for a high voltage distribution box of an electric vehicle according to claim 5, characterized in that: The raised section (111) and the recessed section (901) are both provided with bolt holes (112); and connecting bolts (113) are provided in the bolt holes (112).

7. An electric connection structure for a high voltage distribution box of an electric vehicle according to any one of claims 5 to 6, characterized in that: The positive wiring harness (3) and the negative wiring harness (4) both comprise a first shaft section (12) and a second shaft section (13); the second shaft section (13) is connected to a conductive copper foil (131); the conductive copper foil (131) is connected to a shielding ring (132); the slot (11) comprises a first slot (114) and a second slot (115); the shielding ring (132) is tightly pressed against an inner wall of the second slot (115).

8. An electric vehicle high voltage distribution box electrical connection structure according to claim 7, characterized in that: A sealing rubber ring (121) is provided on the first shaft section (12); the sealing rubber ring (121) is provided on one side of the wiring harness fixing frame (9); and the sealing rubber ring (121) is tightly pressed against the inner wall of the first clamping groove (114).

9. An electric vehicle high voltage distribution box electrical connection structure according to claim 8, characterized in that: The wiring harness fixing frame (9) comprises an upper fixing frame (902) and a lower fixing frame (903); the wiring harness structure is connected between the upper fixing frame (902) and the lower fixing frame (903); the wiring harness fixing frame (9) is provided with a positive wiring harness hole (904) and a negative wiring harness hole (905); the positive wiring harness (3) is arranged in the positive wiring harness hole (904); the negative wiring harness (4) is arranged in the negative wiring harness hole (905); a support (803) is provided at the bottom of the guide frame (8); the support (803) is connected to the distribution box (1).

10. An assembly method for the electric connection structure of the high-voltage distribution box of an electric vehicle according to any one of claims 1 to 9, characterized in that: The assembly method comprises the following steps: S1: Insert the wiring harness fixing frame (9) into the slot (11) of the connecting sleeve (10); insert the positive electrode pin (301) into the positive electrode socket (5); and insert the negative electrode pin (401) into the negative electrode socket (6); S2: Connect the connecting bolt (113) into the bolt hole (112).

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