PDU copper bar design method and system based on combination of simulation and actual measurement, terminal and storage medium

Abstract

The invention relates to a PDU copper bar design method and system based on combination of simulation and actual measurement, a terminal and a storage medium, the PDU copper bar design method based on combination of simulation and actual measurement comprises the following steps: respectively inputting three-dimensional models of a plurality of PDU copper bars with different sectional areas into a simulation model for simulation test, a simulation result of each PDU copper bar is obtained; performing actual measurement on each PDU copper bar by using an actual measurement platform to obtain an actual measurement result of each PDU copper bar; and comparing the simulation result of each PDU copper bar with an actual measurement result, correcting and optimizing the simulation model according to a comparison result, and optimizing the sectional area of each PDU copper bar. According to the method, the simulation technology and the actual measurement technology are comprehensively applied, the overcurrent state of the designed PDU copper bar under various working conditions in the actual operation environment can be known, and the overcurrent capacity and the performance stability of the PDU copper bar are remarkably improved by means of optimizing the sectional area of the copper bar, improving the heat dissipation structure, selecting high-performance copper materials and the like.

Description

Technical Field

[0001] The present invention relates to the technical field of PDU copper busbar design, and in particular to a PDU copper busbar design method based on the combination of simulation and actual measurement, and a system, terminal and storage medium thereof. Background Art

[0002] The traditional PDU (Power Distribution Unit) copper busbar design mainly focuses on the conductivity and structural layout of the copper busbar to ensure stable current transmission under normal operation. However, with the continuous growth of vehicle demand and the increasing complexity of power distribution equipment, PDUs often need to withstand higher peak discharge currents and more complex operating environments. In this case, the traditional PDU copper busbar design gradually exposes its problems of insufficient overcurrent capacity and excessive temperature rise.

[0003] In the existing technology, the PDU copper busbar generally has a single cross-section. The current capacity of the PDU copper busbar is improved by increasing the cross-sectional area of ​​the copper busbar and optimizing the heat dissipation structure, but these solutions often lack systematicity and accuracy. On the one hand, simply increasing the cross-sectional area of ​​the copper busbar can improve its conductivity, but it will also increase costs and occupy more space; on the other hand, there are many factors to consider when optimizing the heat dissipation structure, such as heat dissipation method, heat dissipation area, heat dissipation efficiency, etc. Simple improvements are difficult to achieve ideal results.

[0004] Although the existing PDU copper busbar design has been applied to power battery systems to a certain extent, there are still many problems and challenges in actual application. These problems directly affect the performance and reliability of the PDU, especially when dealing with high loads and complex environments.

[0005] First, the PDU copper busbar design in the prior art often lacks comprehensive consideration of overcurrent capacity. In vehicle systems, current fluctuations and peak discharge currents are normal, while traditional copper busbar designs often only focus on stable operation at rated currents, lacking sufficient attention and effective solutions for high peak current carrying capacity. This results in copper busbars being prone to overheating, fusing and other faults under high load conditions, which seriously affects the stable operation of the system.

[0006] In traditional copper busbar design, the parameters of the copper busbar are generally designed according to experience and several formulas in accordance with the working conditions. This design state can only understand part of the performance of the copper busbar, and potential design problems are not easy to be discovered. It is often necessary to wait until the actual PDU sample is made and tested to discover the problem, which prolongs the design time and increases the design cost.

[0007] In addition, the material selection of PDU copper busbars in the prior art also has certain limitations. The traditional copper busbar material is pure copper, which has good electrical conductivity, but its performance and stability are easily affected in harsh environments such as high load and high temperature. Moreover, although some new materials have better performance, they have not been widely used due to factors such as cost and processing difficulty.

[0008] The existing methods for testing and evaluating the performance of PDU copper busbars also have shortcomings. Traditional testing methods often only focus on performance under a single condition, while ignoring the various complex factors that may exist in the actual operating environment. This results in a large deviation between the test results and the actual performance, making it difficult to accurately evaluate the performance and reliability of the PDU copper busbar. Summary of the invention

[0009] Based on this, the purpose of the present invention is to provide a PDU copper busbar design method based on the combination of simulation and actual measurement, and its system, terminal and storage medium, which combines simulation and actual measurement technology to achieve accurate evaluation and optimization of the current carrying capacity of the PDU copper busbar. Through simulation technology, the operation of the copper busbar under different working environments and current conditions can be simulated, and its temperature distribution and current carrying capacity can be predicted; and the actual measurement technology can verify and correct the simulation results to ensure the accuracy and reliability of the design; this method of combining simulation and actual measurement not only improves the design efficiency, but also reduces the development cost.

[0010] To achieve the above object, the present invention adopts the following technical solutions:

[0011] The present invention first provides a PDU copper busbar design method based on the combination of simulation and actual measurement, which includes the following steps:

[0012] S1. The three-dimensional models of several PDU copper bars with different cross-sectional areas are input into the simulation model for simulation testing to obtain the simulation results of each PDU copper bar;

[0013] S2. Use the measurement platform to measure the copper busbars of each PDU to obtain the measured results of the copper busbars of each PDU;

[0014] S3. Compare the simulation results of each PDU copper busbar with the measured results, modify and optimize the simulation model according to the comparison results, and optimize the cross-sectional area of ​​each PDU copper busbar.

[0015] As a further improvement of the above scheme of the present invention, in step S1, the simulation test includes: performing simulation tests on each of the PDU copper busbars by simulating different simulation working conditions through the simulation model, setting multiple simulation temperature collection points on each of the PDU copper busbars and acquiring the temperature of each of the simulation temperature collection points in real time.

[0016] As a further improvement of the above scheme of the present invention, in step S2, the actual measurement includes: simulating different actual measurement conditions through the actual measurement platform to measure each of the PDU copper busbars, setting multiple actual measurement temperature collection points on each of the PDU copper busbars and acquiring the temperature of each of the actual measurement temperature collection points in real time.

[0017] As a further improvement of the above solution of the present invention, the simulated working condition of the PDU copper busbar is kept consistent with the actual measured working condition.

[0018] As a further improvement of the above solution of the present invention, in step S2, the plurality of PDU copper busbar entities are all made of copper-silver alloy.

[0019] As a further improvement of the above solution of the present invention, in step S3, the optimizing the cross-sectional area of ​​each PDU copper busbar includes: increasing the cross-sectional area of ​​each PDU copper busbar.

[0020] As a further improvement of the above scheme of the present invention, the step S3 further includes: according to the comparison result, designing a composite PDU copper busbar having a plurality of cross-sectional areas, and using the measurement platform to measure the composite PDU copper busbar. According to the installation requirements of the Hall sensor, the overlap requirements of the shunt, and the overcurrent requirements of the branch, the cross-sectional areas of the composite PDU copper busbar are designed so that the obtained composite PDU copper busbar meets the installation requirements of the Hall sensor, the overlap requirements of the shunt, and the overcurrent requirements of the branch.

[0021] The present invention also provides a PDU copper busbar design system based on the combination of simulation and actual measurement, which includes:

[0022] The simulation module inputs three-dimensional models of several PDU copper bars with different cross-sectional areas into the simulation model for simulation testing to obtain simulation results of each of the PDU copper bars;

[0023] A measurement module, using a measurement platform to measure each of the PDU copper bars to obtain measurement results of each of the PDU copper bars; and

[0024] The optimization module compares the simulation results of each PDU copper busbar with the measured results, modifies and optimizes the simulation model according to the comparison results, and optimizes the cross-sectional area of ​​each PDU copper busbar.

[0025] The present invention also provides a computer terminal, which includes a memory, a processor, and a computer program stored in the memory and executable on the processor. When the processor executes the program, the steps of the PDU copper busbar design method based on the combination of simulation and actual measurement as described above are implemented.

[0026] The present invention also provides a computer-readable storage medium having a computer program stored thereon, and when the program is executed by a processor, the steps of the PDU copper busbar design method based on the combination of simulation and actual measurement as described above are implemented.

[0027] Compared with the prior art, the present invention has the following beneficial effects:

[0028] 1. The present invention uses a comprehensive application of simulation technology and actual measurement technology to conduct a test box evaluation on the designed PDU copper busbar. According to the simulation and actual measurement results, the overcurrent state of the designed PDU copper busbar under various working conditions in the actual operating environment can be understood, and a copper busbar that meets the requirements and has better performance can be conveniently designed. By optimizing the cross-sectional area of ​​the copper busbar, improving the heat dissipation structure, and selecting high-performance copper materials, the overcurrent capacity and performance stability of the PDU copper busbar are significantly improved.

[0029] 2. In the simulation stage, the present invention simulates and analyzes the temperature distribution, current density and other parameters of the PDU copper busbar under different current conditions. Through the simulation results, the performance of the PDU copper busbar under certain working conditions can be predicted in advance, and potential design problems can be discovered based on the simulation results.

[0030] 3. During the actual measurement stage, the present invention tests the actual PDU copper busbar to restore the actual working environment of the PDU copper busbar, sets multiple temperature collection points for the copper busbar, obtains key measured data such as temperature and current of the PDU copper busbar during actual operation, compares and verifies the obtained measured data with the simulation results, further corrects and optimizes the simulation model, improves the accuracy of the simulation model, and improves the accuracy of the PDU copper busbar design.

[0031] 4. According to the simulation and measured results of several PDU copper bars with different cross-sectional areas, the present invention also designs a composite PDU copper bar. The composite PDU copper bar has several different cross-sectional areas, which can optimize the current distribution, improve the conductivity of the copper bar, and enhance its mechanical strength. At the same time, the composite cross-sectional design can also effectively reduce the concentrated distribution of current in the copper bar, reduce the risk of local overheating, and further improve the overcurrent capacity of the copper bar. Through the composite cross-sectional integrated design, the overlap surface between the copper bars can also be reduced. After optimization, the PDU copper bar can be used to connect high-voltage connectors, Hall sensors, and shunts at the same time. The copper bars with different cross-sections are naturally connected to avoid additional overlaps, which greatly reduces the overlap area and contact resistance of the copper bar, thereby reducing the heat generated by the heating copper bar, saving material costs, and facilitating rapid assembly. The thermal management strategy is integrated into the composite cross-sectional design, and the cross-sectional area is additionally increased at the current confluence, the overcurrent and heat dissipation capacity is increased, and heat dissipation fins are used to ensure that the copper bar can effectively dissipate heat during operation.

[0032] 5. The present invention uses a method that combines simulation with actual measurement to finely design the structure and materials of the PDU copper busbar, significantly improving the current carrying capacity of the PDU copper busbar, which is particularly important under high load or transient current impact. It improves the conductivity of the copper busbar under different circuit environments, limits the local overheating of the copper busbar, and increases the mechanical strength to prevent failures and damage caused by current overload, thereby ensuring the stable and reliable operation of the power distribution system. The use of a composite cross-section design and the selection of copper-silver alloy materials with excellent electrical conductivity, heat resistance and mechanical strength not only further enhance the current carrying capacity of the PDU copper busbar, but also improve its overall performance and durability. This innovation in material selection provides a strong guarantee for the stable operation of the power distribution system. The copper busbar designed by the present invention can significantly improve the stability and reliability of the power distribution system, thereby reducing downtime and maintenance costs caused by equipment failures. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 A flow chart of a PDU copper busbar design method based on a combination of simulation and actual measurement proposed in an embodiment of the present invention;

[0034] Figure 2 This is a simulation test diagram of copper busbar 1 and copper busbar 2 in an embodiment of the present invention;

[0035] Figure 3 This is a simulated temperature rise curve diagram of the copper busbar 1 under working condition 1 in an embodiment of the present invention;

[0036] Figure 4 This is a simulated temperature rise curve diagram of the copper busbar 1 under working condition 2 in an embodiment of the present invention;

[0037] Figure 5 This is a simulated temperature rise curve diagram of the copper busbar 2 under working condition 3 in an embodiment of the present invention;

[0038] Figure 6 This is a simulated temperature rise curve diagram of the copper busbar 2 under working condition 4 in an embodiment of the present invention;

[0039] Figure 7 This is a schematic diagram of the temperature measurement points of the copper busbar during actual measurement in an embodiment of the present invention;

[0040] Figure 8 This is a measured temperature rise curve of the copper busbar 1 under working condition 1 in an embodiment of the present invention;

[0041] Fig. 9 This is a measured temperature rise curve of the copper busbar 1 under working condition 2 in an embodiment of the present invention;

[0042] Fig.10 This is a measured temperature rise curve of the copper busbar 2 under working condition 3 in an embodiment of the present invention;

[0043] Fig.11This is a measured temperature rise curve of the copper busbar 2 under working condition 4 in an embodiment of the present invention;

[0044] Fig.12 This is a schematic diagram of the optimized PDU copper busbar structure in an embodiment of the present invention;

[0045] Fig.13 This is a schematic diagram of the structure of the optimized PDU copper busbar equipped with a Hall sensor in an embodiment of the present invention;

[0046] Fig.14 This is a schematic diagram of the structure of the optimized PDU copper bar equipped with heat dissipation fins in an embodiment of the present invention;

[0047] Fig.15 This is a schematic diagram of the structure of the optimized PDU copper busbar assembly shunt in an embodiment of the present invention;

[0048] Fig.16 This is a measured temperature rise curve of the composite PDU copper busbar under working condition 5 in an embodiment of the present invention. DETAILED DESCRIPTION

[0049] For ease of understanding of the present invention, the present invention will be described more fully below in conjunction with specific embodiments. However, the present invention can be implemented in many different forms and is not limited to the embodiments described herein. On the contrary, the purpose of providing these embodiments is to make the disclosure of the present invention more thoroughly understood.

[0050] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those commonly understood by those skilled in the art of the present invention. The terms used in the specification of the present invention herein are only for the purpose of describing specific embodiments and are not intended to limit the present invention.

[0051] Reference Figure 1 This embodiment proposes a PDU copper busbar design method based on a combination of simulation and actual measurement, which includes the following steps:

[0052] S1. Build a simulation model, design several PDU copper busbars with different cross-sectional areas and use software to establish three-dimensional models of several PDU copper busbars respectively, input the three-dimensional models of several PDU copper busbars into the simulation model respectively, use the simulation model to simulate different simulation conditions to perform simulation tests on each PDU copper busbar, set multiple simulation temperature collection points on each PDU copper busbar and obtain the temperature of each simulation temperature collection point in real time to obtain the simulation temperature rise results of each PDU copper busbar.

[0053] When setting the simulated temperature collection points in this embodiment, temperature collection points are set on the plane of the PDU copper busbar and on the overlapping surface of the PDU copper busbar and electrical components, wherein the overlapping surface is the location where the highest temperature appears, and an appropriate number of collection points are set at different positions on the plane of the PDU copper busbar in combination with the length of the PDU copper busbar.

[0054] In this embodiment, the actual working environment of the battery pack is referred to, and the ambient temperature, loop current, overcurrent time and other working condition parameters are set to provide a simulated working condition that conforms to the actual environment. Then, according to the actual use of the battery pack, a simulation experiment that conforms to the actual use of the battery pack is set, and the PDU copper busbar is simulated and tested to obtain the performance results of the copper busbar in the simulation. Through the performance result feedback of the simulation technology, designers can understand in advance the areas that need to be improved in the copper busbar design.

[0055] By simulating and analyzing the temperature distribution, current density and other parameters of the PDU copper busbar under different current conditions, the operation of the copper busbar under different working environments and current conditions is simulated. Through the simulation results, the performance of the copper busbar under various working conditions can be predicted in advance, and potential design problems can be found according to the simulation results. In this embodiment, an advanced simulation software (6SigmaET) is used to build a simulation model, and a three-dimensional model of each PDU copper busbar is established in a three-dimensional modeling software (such as Catia).

[0056] S2. Build a measurement platform, use the measurement platform to simulate different measurement conditions to measure each PDU copper busbar, set multiple measurement temperature collection points on each PDU copper busbar and obtain the temperature of each measurement temperature collection point in real time to obtain the measured temperature rise result of each PDU copper busbar.

[0057] This embodiment uses each PDU copper busbar and fuse as the test object. The existing laboratory equipment is used to directly build a measurement platform to restore the actual working environment of the PDU copper busbar. The same working conditions and experimental steps as those in the simulation technology are set to measure each PDU copper busbar. Multiple data collection points are set for each PDU copper busbar. During the measurement process, the temperature rise data of each PDU copper busbar during the test is collected in real time.

[0058] Through the measured results, we can obtain the real performance data of each PDU copper busbar, so as to verify the accuracy of the simulation results, understand the differences between simulation technology and measured technology, and improve the simulation technology.

[0059] S3. Compare the simulation results of each PDU copper busbar with the measured results, and modify and optimize the simulation model according to the comparison results to improve the accuracy of the simulation model and the accuracy of the PDU copper busbar design. According to the simulation results and measured results of several PDU copper busbars, optimize the cross-sectional area of ​​each PDU copper busbar and design a composite PDU copper busbar with several cross-sectional areas, and use the measurement platform to measure the composite PDU copper busbar.

[0060] Based on the simulation and actual measurement results, we can understand the overcurrent status of PDU copper busbars of various designed cross-sectional areas under various working conditions in the actual operating environment. By optimizing the cross-sectional area of ​​the copper busbar, improving the heat dissipation structure, and selecting high-performance copper materials, we can improve the overcurrent capacity and performance stability of the PDU copper busbar.

[0061] At the same time, a composite cross-section design is also adopted to improve the conductivity and mechanical strength of the PDU copper busbar, and to a certain extent improve the overcurrent capacity of the PDU copper busbar. In this embodiment, according to the installation requirements of the Hall sensor, the overlap requirements of the shunt, and the overcurrent requirements of the branch, the copper busbar with a suitable cross-section is selected and the copper busbar is compounded, so that the obtained PDU copper busbar meets the installation of the Hall sensor, the overlap of the shunt, and the overcurrent of the branch. By cleverly integrating three cross-sections with different functions (installation cross-section, overcurrent cross-section, heat dissipation cross-section) into one copper busbar, this design improves the conductivity of the copper busbar and enhances its mechanical strength by reasonably matching copper busbars with different cross-sections. At the same time, the composite cross-section design can also effectively reduce the concentrated distribution of current in the copper busbar, reduce the risk of local overheating, and further improve the overcurrent capacity of the copper busbar.

[0062] This embodiment aims to significantly improve the current capacity of the PDU copper busbar, optimize the heat dissipation performance, improve material selection, and perfect the performance evaluation and testing methods, thereby promoting the performance improvement and reliability enhancement of the battery system.

[0063] Next, the above solution of this embodiment is described in detail with a specific example.

[0064] S1. Use simulation software (6SigmaET) to build a simulation test model, design copper busbar 1 (branch copper busbar) and copper busbar 2 (main circuit copper busbar) with different cross-sectional areas, and use 3D software to establish the 3D models of copper busbar 1 and copper busbar 2, and input the 3D models of copper busbar 1 and copper busbar 2 into the simulation model respectively, set different working conditions to perform simulation tests on copper busbar 1 and copper busbar 2 respectively, set multiple simulation temperature collection points on copper busbar 1 and copper busbar 2 respectively, and obtain the temperature of each simulation temperature collection point in real time to obtain the simulation temperature rise results of copper busbar 1 and copper busbar 2.

[0065] Copper busbar 1: width*thickness*overcurrent safety factor=18mm*3mm*5, cross-sectional area (width*thickness) is 18mm*3mm=54mm 2 , according to 5 times the overcurrent is 270A; copper bar 2: width * thickness * overcurrent safety factor = 26mm * 4mm * 5, cross-sectional area (width * thickness) is 26mm * 4mm = 104mm 2, according to 5 times the overcurrent is 520 A. In this embodiment, a temperature collection point is set on the plane of copper busbar 1, and two temperature collection points (collection point 1 and collection point 2) are set on the plane of copper busbar 2 at intervals.

[0066] Two working conditions are set for copper busbar 1: working condition 1 and working condition 2. Working condition 1: continuous charge and discharge current is 200A, peak charge and discharge current is 420A, under the condition of ambient temperature of 45°C, 420A@30S+200A@240S is one cycle, and 200 cycles are performed (or the test is stopped when the temperature reaches 130°). Working condition 2: continuous charge and discharge current is 200A, peak charge and discharge current is 420A, under the condition of ambient temperature of 45°, 200A is continued for 2h until the temperature stabilizes, 420A@30S is applied as one cycle, and the next cycle is continued after standing for 5min, and 30 cycles are performed.

[0067] Two working conditions are set for copper busbar 2: working condition 3 and working condition 4. Among them, working condition 3: continuous charge and discharge current is 400A, peak charge and discharge current is 840A, under the condition of ambient temperature of 45°, 839A@30S+400A@240S is one cycle, and 200 cycles are performed (or the test is stopped when the temperature reaches 130°). Working condition 4: continuous charge and discharge current is 400A, peak charge and discharge current is 840A, under the condition of ambient temperature of 45°, 400A is continued for 2h until the temperature stabilizes, and 839A@30S is applied as one cycle, and the next cycle is continued after standing for 5min, and 30 cycles are performed.

[0068] like Figure 2 As shown, the copper busbar 1 is simulated and tested under working conditions 1 and 2, and the simulated temperature rise results of the copper busbar 1 at different temperature points are recorded. The copper busbar 2 is simulated and tested under working conditions 3 and 4, and the simulated temperature rise results of the copper busbar 2 at different temperature points are recorded. Figure 3 This is the simulated temperature rise curve of copper busbar 1 in working condition 1. Figure 4 This is the simulated temperature rise curve of copper busbar 1 in working condition 2. Figure 5 This is the simulated temperature rise curve of copper busbar 2 in working condition 3. Figure 6 This is the simulated temperature rise curve of copper busbar 2 in working condition 4.

[0069] S2. Build a measurement platform to restore the actual working environment of the battery pack, and use copper-silver alloy to make copper bar 1 and copper bar 2 entities. Use the measurement platform to measure copper bar 1 and copper bar 2 respectively, set multiple measured temperature collection points on the entities of copper bar 1 and copper bar 2 respectively, and obtain the temperature of each measured temperature collection point in real time to obtain the measured temperature rise results of copper bar 1 and copper bar 2 entities.

[0070] Copper bar 1 sample and copper bar 2 sample were respectively made according to the three-dimensional models of copper bar 1 and copper bar 2. In this embodiment, copper bar 1 and copper bar 2 are made of copper-silver alloy, which has excellent electrical conductivity, heat resistance and mechanical strength. Copper-silver alloy has both the excellent electrical conductivity and processability of copper and the high thermal conductivity and oxidation resistance of silver, and can maintain stable performance under high current load while resisting high temperature and corrosion.

[0071] During the actual measurement, assemble the two copper bars 1 on the left and right sides of the fuse, and then assemble the fuse on the actual measurement platform. Figure 7 As shown, select the fuse housing, the copper bar terminal A on the right side of the fuse, the middle of the copper bar on the right side of the fuse, the right end of the copper bar on the right side of the fuse, the copper bar terminal B on the left side of the fuse, the middle of the copper bar on the left side of the fuse, and the left end of the copper bar on the left side of the fuse as the temperature measurement points; similarly, assemble the two copper bars 2 on the left and right sides of the fuse respectively, and then assemble the fuse on the actual measurement platform, as shown in Figure 1. Figure 7 As shown, select the fuse housing, the copper bar terminal A on the right side of the fuse, the middle of the copper bar on the right side of the fuse, the right end of the copper bar on the right side of the fuse, the copper bar terminal B on the left side of the fuse, the middle of the copper bar on the left side of the fuse, and the left end of the copper bar on the left side of the fuse as the temperature measurement points.

[0072] Specifically, the copper busbar 1 is placed under the above working conditions 1 and 2 for actual measurement, and the measured temperature rise results of the copper busbar 1 at different temperature points are recorded. Figure 8 This is the measured temperature rise curve of copper busbar 1 in working condition 1. Fig. 9 The measured temperature rise curve of copper bar 1 in working condition 2 is shown in Figure 2. The copper bar 2 is placed in working condition 3 and working condition 4 for actual measurement, and the measured temperature rise results of copper bar 2 at different temperature points are recorded. Fig.10 This is the measured temperature rise curve of copper busbar 2 in working condition 3. Fig.11 This is the measured temperature rise curve of copper busbar 2 in working condition 4.

[0073] S3. Compare and verify the above measured temperature rise results with the simulated temperature rise results, further correct and optimize the simulation model, and improve the accuracy of the simulation model, which can improve the accuracy of the PDU copper busbar design. According to the simulated temperature rise results and measured temperature rise results of the above copper busbar 1 and copper busbar 2, optimize the cross-sectional area of ​​copper busbar 1 and copper busbar 2 and design a composite PDU copper busbar, and use the actual measurement platform to measure the composite PDU copper busbar.

[0074] from Figure 3 , Figure 4 , Figure 8 , Fig. 9 It can be seen that the cross-sectional area is 54mm 2 In the simulation and actual measurement results of the copper busbar with a continuous current of 200A, the 54mm 2The simulated temperature of the copper busbar (middle) is stable between 80℃ and 90℃, while the measured temperature is between 90℃ and 98℃. It can be seen that the temperature rise difference between the simulated and measured copper busbar with a cross-sectional area of ​​54mm2 is within 10℃. 2 The simulated temperature of the copper busbar is basically consistent with the measured temperature.

[0075] from Figure 5 , Figure 6 , Fig.10 , Fig.11 It can be seen that in the simulation and measured results of the copper busbar with a cross-sectional area of ​​104mm2 and a continuous current of 400A, 2 The simulated temperature of the copper busbar (middle) is stable between 110℃ and 120℃, while the measured temperature is between 130℃ and 160℃. The cross-sectional area is 104mm 2 There is a difference of about 20°C between the simulated temperature and the measured temperature of the copper busbar.

[0076] By comparing the simulation and measured data of copper busbars with different cross-sectional areas under different current environments, it can be found that the simulation technology has good consistency with the measured data in the prediction results of the temperature rise of copper busbar 1 with a small cross-sectional area when the current is low. However, when the current is large, for copper busbar 2 with a larger cross-sectional area, the simulation technology has a significant deviation from the measured results in terms of predicted temperature rise. This shows that the prediction of the temperature rise state of copper busbars with large cross-sectional areas under high current conditions requires a more accurate combination of simulation technology and measurement technology. At the same time, in actual design, consideration should be given to increasing the cross-sectional area of ​​the copper busbar to improve its current capacity, thereby effectively reducing the temperature rise of the copper busbar when working at high current, and ensuring the safe and stable operation of the system. To this end, the cross-sectional area of ​​copper busbar 1 is optimized to 30mm*3mm=90mm 2 , optimize the cross-sectional area of ​​copper busbar 2 to 35mm*4mm=140mm 2 .

[0077] like Fig.12 As shown, this embodiment also designs a composite PDU copper busbar with three different cross-sectional areas, and the three different cross-sectional areas are defined as cross-sectional area I, cross-sectional area II, and cross-sectional area III, wherein cross-sectional area I (18 mm*5 mm=90 mm 2 ) is set on the branch road, section II (25.5mm*5mm=127.5mm 2 ) is the merging loop between branches, section III (33.5mm*5mm=167.5mm 2 ) is the actual overlapping loop cross-section of the shunt.

[0078] Section I (installation section) is designed as a narrow rectangle (18mm*5mm=90mm 2), is designed to meet the installation requirements of the Hall sensor, while ensuring that it has sufficient flow area to ensure smooth current transmission, such as Fig.13 shown.

[0079] Section II (heat dissipation section) is designed with a heat dissipation fin shape (25.5mm*5mm=127.5mm 2 ), without affecting the copper busbar's fixation and current capacity, add heat dissipation fins to the copper busbar plane to enhance the heat dissipation effect, such as Fig.14 shown.

[0080] Section III (flow section) is designed to be wider (33.5mm*5mm=167.5mm 2 ), meet the installation contact area of ​​the shunt to provide high current carrying capacity in a limited space, such as Fig.15 shown.

[0081] The composite PDU copper busbar sample was made of copper-silver alloy. Two composite PDU copper busbars were assembled on the left and right sides of the fuse respectively, and then the fuse was assembled on the actual measurement platform. Fig.12 As shown, a temperature measuring point is set on section I, section II, and section III, namely temperature measuring point 11, temperature measuring point 9, and temperature measuring point 7, respectively. The composite PDU copper busbar is placed under working condition 5 for actual measurement. Working condition 5: Under ambient temperature of 33°C, charge at 200A for 65min until fully charged, then let stand for 5min, and discharge at 200A until empty. Fig.16 This is the measured temperature rise curve of the composite PDU copper busbar in working condition 5. According to the GB37133-2018 standard, the temperature rise requirement of the copper busbar is <55K. Fig.16 It can be seen that the highest temperature at temperature measuring point 7 is 80°C, the highest temperature at temperature measuring point 9 is 77.3°C, and the highest temperature at temperature measuring point 11 is 68.9°C. It can be seen that the highest temperature of the composite PDU copper busbar in this embodiment is 80°C, and the temperature rise of the composite cross-section copper busbar is 47k, which is lower than the standard requirement.

[0082] This embodiment cleverly integrates three copper bars with different functions (installation section, current flow section, and heat dissipation section) into one copper bar. This design improves the conductivity of the copper bar and enhances its mechanical strength by reasonably matching copper bars with different cross sections. At the same time, the composite cross-section design can also effectively reduce the concentrated distribution of current in the copper bar and reduce the risk of local overheating, thereby further improving the current flow capacity of the copper bar.

[0083] The design of the composite PDU copper busbar of this embodiment reduces the overlap surface: the overlap surface between the copper busbars is reduced through the integrated design of the composite section. The high-voltage connector, Hall sensor, and shunt are connected with one copper busbar, and the copper busbars with different sections are naturally connected to avoid additional overlap, which greatly reduces the overlap area and contact resistance of the copper busbar, thereby reducing the heat generated by the heating copper busbar, saving material costs and facilitating rapid assembly. The thermal management strategy is incorporated into the composite section design, and the cross-sectional area is additionally increased at the current confluence point, the overcurrent and heat dissipation capacity is increased, and heat dissipation fins are used to ensure that the copper busbar can effectively dissipate heat during operation.

[0084] The PDU copper busbars designed in this embodiment include three different cross-sections, which improve the conductivity of the copper busbar in different circuit environments, limit the local overheating of the copper busbar, and increase the mechanical strength. It is suitable for complex circuit environments including multiple components and helps to improve the conductivity of the loop. The target PDU copper busbar of this embodiment connects multiple electrical components, centralizes the PDU layout, saves PDU space, and reduces the manufacturing cost of the copper busbar.

[0085] In terms of materials, the PDU copper busbar uses copper-silver alloy material, which has excellent electrical conductivity, heat resistance and mechanical strength. Combined with the composite cross-section design, the current capacity and service life of the PDU copper busbar are further improved.

[0086] Based on the above PDU copper busbar design method based on the combination of simulation and actual measurement, this embodiment further proposes a PDU copper busbar design system based on the combination of simulation and actual measurement, which includes:

[0087] The simulation module inputs the three-dimensional models of several PDU copper bars with different cross-sectional areas into the simulation model for simulation testing to obtain the simulation results of each PDU copper bar;

[0088] The actual measurement module uses the actual measurement platform to measure each PDU copper busbar and obtain the actual measurement results of each PDU copper busbar;

[0089] The optimization module compares the simulation results of each PDU copper busbar with the measured results, modifies and optimizes the simulation model based on the comparison results, and optimizes the cross-sectional area of ​​each PDU copper busbar; and

[0090] The design module designs a composite PDU copper busbar with several cross-sectional areas according to the comparison results. The measurement module is also used to measure the designed composite PDU copper busbar.

[0091] Based on the above PDU copper busbar design method based on the combination of simulation and actual measurement, this embodiment further proposes a computer terminal, which includes a memory, a processor, and a computer program stored in the memory and executable on the processor. When the processor executes the program, the steps of the above PDU copper busbar design method based on the combination of simulation and actual measurement are implemented.

[0092] Based on the above PDU copper busbar design method based on the combination of simulation and actual measurement, this embodiment further proposes a computer-readable storage medium on which a computer program is stored. When the program is executed by a processor, the steps of the above PDU copper busbar design method based on the combination of simulation and actual measurement are implemented.

[0093] The technical features of the above-described embodiments may be arbitrarily combined. To make the description concise, not all possible combinations of the technical features in the above-described embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0094] The above-mentioned embodiments only express several implementation methods of the present invention, and the descriptions thereof are relatively specific and detailed, but they cannot be understood as limiting the scope of the invention patent. It should be pointed out that, for ordinary technicians in this field, several variations and improvements can be made without departing from the concept of the present invention, and these all belong to the protection scope of the present invention. Therefore, the protection scope of the patent of the present invention shall be subject to the attached claims.

Claims

1. A PDU copper busbar design method based on the combination of simulation and actual measurement, characterized in that: It includes the following steps: S1. The three-dimensional models of several PDU copper bars with different cross-sectional areas are input into the simulation model for simulation testing to obtain the simulation results of each PDU copper bar; S2. Use the measurement platform to measure the copper busbars of each PDU to obtain the measured results of the copper busbars of each PDU; S3. Compare the simulation results of each PDU copper busbar with the measured results, modify and optimize the simulation model according to the comparison results, and optimize the cross-sectional area of ​​each PDU copper busbar.

2. The PDU copper busbar design method based on the combination of simulation and actual measurement according to claim 1 is characterized in that: In step S1, the simulation test includes: performing simulation tests on each of the PDU copper bars by simulating different simulation working conditions through the simulation model, setting a plurality of simulation temperature collection points on each of the PDU copper bars and acquiring the temperature of each of the simulation temperature collection points in real time.

3. The PDU copper busbar design method based on the combination of simulation and actual measurement according to claim 2 is characterized in that: In step S2, the actual measurement includes: simulating different actual measurement conditions through the actual measurement platform to measure each of the PDU copper bars, respectively setting a plurality of actual measurement temperature collection points on each of the PDU copper bars and acquiring the temperature of each of the actual measurement temperature collection points in real time.

4. The PDU copper busbar design method based on the combination of simulation and actual measurement according to claim 3 is characterized in that: The simulated working condition of the PDU copper busbar is consistent with the actual measured working condition.

5. The PDU copper busbar design method based on the combination of simulation and actual measurement according to claim 1 is characterized in that: In step S2, the plurality of PDU copper busbar entities are all made of copper-silver alloy.

6. The PDU copper busbar design method based on the combination of simulation and actual measurement according to claim 1 is characterized in that: In step S3, optimizing the cross-sectional area of ​​each PDU copper busbar includes: increasing the cross-sectional area of ​​each PDU copper busbar.

7. The PDU copper busbar design method based on the combination of simulation and actual measurement according to claim 1 is characterized in that: The step S3 also includes: designing a composite PDU copper busbar having a plurality of cross-sectional areas according to the comparison result, and performing actual measurement on the composite PDU copper busbar using the actual measurement platform.

8. A PDU copper busbar design system based on the combination of simulation and actual measurement, characterized in that: It includes: The simulation module inputs three-dimensional models of several PDU copper bars with different cross-sectional areas into the simulation model for simulation testing to obtain simulation results of each of the PDU copper bars; The measuring module uses the measuring platform to measure the PDU copper busbars to obtain the measuring results of the PDU copper busbars. as well as The optimization module compares the simulation results of each PDU copper busbar with the measured results, modifies and optimizes the simulation model according to the comparison results, and optimizes the cross-sectional area of ​​each PDU copper busbar.

9. A computer terminal comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that: When the processor executes the program, the steps of the PDU copper busbar design method based on the combination of simulation and actual measurement as described in any one of claims 1-7 are implemented.

10. A computer-readable storage medium having a computer program stored thereon, characterized in that: When the program is executed by the processor, the steps of the PDU copper busbar design method based on the combination of simulation and actual measurement as described in any one of claims 1 to 7 are implemented.

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