Commercial vehicle domain control battery pack and commercial vehicle

Abstract

The invention relates to a commercial vehicle domain control battery pack and a commercial vehicle, and belongs to the technical field of new energy high-voltage power batteries. The domain control battery pack comprises a battery PACK and a domain control module, the domain control module comprises a positive bus and a negative bus, and the positive bus and the negative bus are respectively connected with the positive electrode and the negative electrode of the battery PACK through a connector; the domain control module is provided with a motor driving port used for driving a motor, a fast charging port used for direct current charging, an alternating current charging port used for alternating current charging and a direct current output port. The positive bus and the negative bus are connected with a motor driving port through a motor controller, are connected with a fast charging port through a charging contactor, and are respectively connected with an alternating current charging port and a direct current output port through an OBC and a DCDC; the domain control module comprises a domain control mainboard, and the domain control mainboard is integrated with a BMS, a VCU, a BCM, an OBC, a DCDC, a PDU, a TMS, a gateway and a motor controller. Through structural component integration and high-voltage and low-voltage component integration, the integration level of the three-power system is improved, cost and weight are reduced, and the problems that the number of high-voltage and low-voltage components and the number of wiring harnesses of a vehicle are large are solved.

Description

Technical Field

[0001] The present invention discloses a commercial vehicle domain control battery pack and a commercial vehicle, belonging to the technical field of new energy high-voltage power batteries; in particular, it relates to a high-voltage power battery system for commercial vehicles (buses, trucks, mining vehicles, cleaning vehicles, etc.). Background Art

[0002] The total number of parts in the three-electric (battery, electric drive, and electronic control) system of electric vehicles is large, including power battery box (Pack), battery management system (BMS), motor controller (MCU), vehicle controller (VCU), on-board AC charger (OBC), voltage conversion device (DCDC), power distribution unit (PDU), body controller (BCM), thermal management controller (TMS), gateway, etc. Domestic commercial vehicles currently mostly use traditional fuel vehicle chassis, and the battery system is distributed. There is no electrified chassis battery product, which is far behind the technical level of passenger cars and foreign advanced commercial vehicles. As a result, there are many high- and low-voltage wire harnesses and high- and low-voltage connectors inside the three-electric system, which further leads to a high failure rate of the whole vehicle; at the same time, the total weight of the three-electric system is large, and the installation process of the whole vehicle is complex, the system development cycle is long, and the cost is high.

[0003] With the further development of pure electric new energy vehicles, there are more and more three-electric system integration solutions for different architectures of pure electric vehicles, but the overall idea is still limited to high-voltage system integration and low-voltage system integration, and the degree of integration is not high. The competitiveness of their application in new energy commercial vehicles with high spatial layout requirements is poor.

[0004] The Chinese invention patent application with application publication number CN116365149A discloses a domain control battery pack and vehicle. The solution integrates the domain control components on the battery box housing and adopts a design that is easy to disassemble, making it easy to check and repair faults. However, the solution is mainly a structural improvement and does not involve the integrated design of the domain control and high and low voltage systems.

[0005] The Chinese invention patent application with application publication number CN117818387A discloses a domain control battery pack and a complete vehicle. This solution installs various control modules, high and low voltage system components, copper bars and wiring harnesses directly together with the battery modules in the battery box, and reserves high and low voltage, signal and liquid cooling interfaces on the side panels of the box. Although the solution installs high and low voltage components such as BMS, BDU (battery energy distribution unit), DCDC in the battery box, the integration of the three-electric system is still insufficient; and the entire battery box needs to be disassembled for maintenance, and it is not easy to realize modular replacement of components, which increases the difficulty of operation and maintenance. Summary of the invention

[0006] The purpose of the present invention is to provide a commercial vehicle domain control battery pack and a commercial vehicle, so as to solve the problems of low integration and complex structure of the three-electric system of existing electric vehicles.

[0007] To achieve the above object, the solution of the present invention includes: A technical solution of a domain-controlled battery pack for a commercial vehicle of the present invention comprises a battery PACK and a domain control module, wherein the domain control module comprises positive and negative busbars, which are respectively connected to the positive and negative electrodes of the battery PACK through connectors; the domain control module is provided with a motor drive port for driving a motor, a fast charge port for DC charging, an AC charging port for AC charging, and a DC output port; the positive and negative busbars are connected to the motor drive port through a motor controller, connected to the fast charge port through a charging contactor, and respectively connected to the AC charging port and the DC output port through OBC and DCDC; the domain control module comprises a domain control mainboard, which integrates a BMS, a VCU, a BCM, an OBC, a DCDC, a PDU, a TMS, a gateway, and a motor controller.

[0008] Furthermore, the domain control mainboard integrates the algorithms of BMS, VCU, BCM, OBC, DCDC, PDU, TMS, gateway and motor controller into one chip, and realizes chip computing power multiplexing through a circuit board; the hardware also integrates the power module, distribution module and drive module of BMS, VCU, BCM, OBC, DCDC, PDU, TMS, gateway and motor controller.

[0009] Furthermore, the domain control motherboard software part adopts the AutoSar tool chain for layered development, the upper application layer is isolated from the lower basic software, and standardized interactive interfaces and software component models are used to improve the software reuse capabilities of each layer, thereby reducing development costs and increasing the speed of system integration and product launch.

[0010] Furthermore, the battery PACK leaves an opening and space at one end as an insertion position for the domain control module. The part of the domain control module extending into the insertion position realizes the connection between the positive and negative busbars and the positive and negative electrodes through a connector. The end panel at the corresponding end of the battery PACK serves as a sealing surface, which is sealed and fixedly connected to the domain control module to realize the sealing of the battery PACK. The fixation and sealing of the domain control module are completed without changing other structures of the battery PACK.

[0011] Furthermore, the battery PACK extends out of the mounting bracket at one end, the battery PACK and the domain control module are sealed independently, and after the battery PACK and the domain control module are connected through a floating plug connector, the domain control module is fixed on the mounting bracket.

[0012] A technical solution for a commercial vehicle of the present invention includes a domain control battery pack, wherein the domain control battery pack includes a battery PACK and a domain control module, wherein the domain control module includes positive and negative bus bars, which are respectively connected to the positive and negative poles of the battery PACK through connectors; the domain control module is provided with a motor drive port for driving a motor, a fast charge port for DC charging, an AC charging port for AC charging, and a DC output port; the positive and negative bus bars are connected to the motor drive port through a motor controller, connected to the fast charge port through a charging contactor, and connected to the AC charging port and the DC output port through OBC and DCDC, respectively; the domain control module includes a domain control mainboard, which integrates a BMS, a VCU, a BCM, an OBC, a DCDC, a PDU, a TMS, a gateway, and a motor controller.

[0013] Furthermore, the domain control mainboard integrates the algorithms of BMS, VCU, BCM, OBC, DCDC, PDU, TMS, gateway and motor controller into one chip, and realizes chip computing power multiplexing through a circuit board; the hardware also integrates the power module, distribution module and drive module of BMS, VCU, BCM, OBC, DCDC, PDU, TMS, gateway and motor controller.

[0014] Furthermore, the domain control motherboard software part adopts the AutoSar tool chain for layered development, the upper application layer is isolated from the lower basic software, and standardized interactive interfaces and software component models are used to improve the software reuse capabilities of each layer, thereby reducing development costs and increasing the speed of system integration and product launch.

[0015] Furthermore, the battery PACK leaves an opening and space at one end as an insertion position for the domain control module. The part of the domain control module extending into the insertion position realizes the connection between the positive and negative busbars and the positive and negative electrodes through a connector. The end panel at the corresponding end of the battery PACK serves as a sealing surface, which is sealed and fixedly connected to the domain control module to realize the sealing of the battery PACK. The fixation and sealing of the domain control module are completed without changing other structures of the battery PACK.

[0016] Furthermore, the battery PACK extends out of the mounting bracket at one end, the battery PACK and the domain control module are sealed independently, and after the battery PACK and the domain control module are connected through a floating plug connector, the domain control module is fixed on the mounting bracket.

[0017] The beneficial effects of the present invention are as follows: the present invention provides a domain-controlled battery pack and a commercial vehicle using the domain-controlled battery pack. The domain-controlled battery pack of the present invention further improves the integration of the three-electric system of electric vehicles, integrates BMS, MCU, VCU, BCM, OBC, DCDC, PDU, TMS and gateway together, and greatly improves the integration of commercial vehicle components through structural parts integration, high and low voltage component integration, and thermal management system integration, reduces the cost, weight and assembly process, and solves the problems of many high and low voltage components in the vehicle, many wiring harnesses between components, and low integration of the whole vehicle. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is a schematic diagram of the composition of the domain control battery pack for commercial vehicles of the present invention; Figure 2 It is a schematic diagram of the structure of the domain control module 20 of the commercial vehicle domain control battery pack of the present invention; Figure 3 is an integrated schematic diagram of a domain control mainboard 21 of a domain control module 20; Figure 4 It is a schematic diagram of the AUTOSAR architecture adopted by the domain control module 20 software; Figure 5 It is a circuit schematic diagram of a commercial vehicle domain control battery pack of the present invention; Figure 6 It is a schematic diagram of the end structure of the battery PACK10 in the first integration mode of the battery PACK10 and the domain control module 20 of the present invention; FIG. 7 ( a ) is a schematic diagram of a second integration method of a battery PACK 10 and a domain control module 20 of the present invention; FIG. 7 ( b ) is a schematic diagram of the end structure of the battery PACK 10 in the second integration mode of the battery PACK 10 and the domain control module 20 of the present invention; FIG. 7 ( c ) is a schematic structural diagram of the domain control module 20 in the second integration mode of the battery PACK 10 and the domain control module 20 of the present invention; FIG8 (a) is a schematic diagram of a third integration method of a battery PACK 10 and a domain control module 20 of the present invention; FIG8 ( b ) is a schematic diagram of a third integration method of the battery PACK 10 and the domain control module 20 from another angle of the present invention; FIG8( c ) is a schematic structural diagram of a third integration method of a battery PACK 10 and a domain control module 20 according to the present invention. DETAILED DESCRIPTION

[0019] In order to make the purpose, technical solutions and advantages of the present invention more clear, the present invention is described in detail in a clear and complete manner in conjunction with the accompanying drawings and embodiments.

[0020] In order to solve the problems of scattered layout and low integration efficiency of commercial vehicle power battery systems, the present invention develops chassis battery technology and domain control integration technology. Based on the technical conditions of the whole vehicle chassis, BMS, MCU, VCU, and BCM are integrated into a chip, a circuit board, and a software system, and the control strategies of OBC, DCDC, PDU, and TMS are integrated at the same time. The hardware also integrates the power module, distribution module, and drive module to form an all-in-one integrated control panel, which is then integrated with the battery PACK to form the domain control battery pack of the present invention. Through the integration of structural parts, high and low voltage components, and thermal management system, the integration of commercial vehicle components is greatly improved, solving the problems of many high and low voltage components in the vehicle, many wiring harnesses between components, and low integration of the whole vehicle.

[0021] Based on the selection of high-energy-density battery cells, the present invention achieves efficient integration of the battery system and chassis through the matching of the "mechanical-electrical-thermal" functions of the chassis and the battery and the integration of components, thereby reducing structural complexity, reducing failure points, improving reliability, reducing costs and weight, and supporting the improvement of the vehicle's endurance.

[0022] In response to the design requirements for efficient integrated application of chassis batteries for commercial vehicle electrification, system research and solution design are carried out from the perspective of the "mechanical-electrical-thermal" integrated integration of the battery system; in terms of mechanical integration, structural sharing, functional fusion and space reuse can be achieved, and efficient use of chassis and battery layout space can be achieved; in terms of electrical integration, high and low voltage components are integrated into one, reducing high and low voltage wiring harnesses and high and low voltage connectors, and achieving efficient integrated power distribution; thermal management integration is achieved through the chassis frame-guard plate-battery box integrated insulation integrated architecture and a multiphase flow battery thermal management system, to develop a high-pressure refrigerant direct-cooled battery system with a multifunctional reused integrated insulation system, to achieve efficient integrated thermal management of chassis batteries.

[0023] Battery pack example: like Figure 1 As shown, the commercial vehicle domain control battery pack of this embodiment includes a battery PACK10 and a domain control module 20. The domain control module 20 is inserted into the opening at one end of the battery PACK10 to fix and seal the battery PACK10, thereby constituting a commercial vehicle domain control battery pack of the present invention.

[0024] Domain control module 20 Figure 2 As shown ( Figure 2 The domain control module shown in Figure 1The appearance and structure of the domain control module 20 are slightly different, but it does not affect the introduction of the domain control module 20 in this embodiment), including a domain control mainboard 21, a low-voltage connector 22 for outputting low-voltage power to the outside, and a power module 27 of the domain control mainboard 21; it also includes a PDU board 24, a high-voltage connector 23 for outputting high-voltage power to the outside, and a main relay 25 and a main fuse 26 connected between the battery PACK10 and the PDU board 24.

[0025] Specifically, for the domain control mainboard 21, Figure 3 As shown, through the domain control integration technology, the algorithm / control strategy of the vehicle battery management system BMS, motor controller MCU, vehicle controller VCU, vehicle body control BCM, on-board charger OBC, high-voltage to low-voltage DCDC, power distribution unit (high-voltage distribution box) PDU, gateway, thermal management controller TMS are integrated into one chip, and the chip computing power is reused through a circuit board; the hardware integrates the power module, distribution module, and drive module of BMS, MCU, VCU, BCM, OBC, DCDC, PDU, gateway, and TMS to form an all-in-one integrated control panel (domain control motherboard 21), which is then integrated with the battery PACK10 to form the domain control battery pack of the present invention. The software part adopts the AutoSar tool chain for layered development and design. The upper application layer is isolated from the lower basic software. Standardized interactive interfaces and software component models are used to improve the software reuse capabilities of each layer, thereby reducing development costs and increasing the speed of system integration and product launch.

[0026] Specifically, Figure 4 As shown, the domain control module 20 software adopts the AUTOSAR architecture, and the domain control panel software is divided into an application software layer (including BMS, VCU, MCU, OBC, DCDC, PDU, BDU, gateway, TMS), a real-time operating environment layer, and a basic software layer; the software modules of each layer are independently developed and run through an interface, thus realizing the functional decoupling, logical separation, and centralized decision-making management method of the domain controller, and supporting OTA independent upgrade and maintenance of the application layer software, for example, only the BMS software can be upgraded while other software modules are not upgraded; at the same time, through the sharing of computing power resources, hardware sharing in mutually exclusive scenarios can be achieved, such as the storage space and computing power used during driving can be allocated to the BMS software call to realize hardware resource reuse scheduling.

[0027] At different times, the algorithm centrally controls the data according to needs by collecting signals from a variety of sensors, customizing monitoring data of different periods and fields, and achieving intelligent and efficient communication between cores and between vehicles and the cloud.

[0028] The circuit principle of the commercial vehicle domain control battery pack of this embodiment is as follows Figure 5As shown, the interior of the battery PACK 10 is basically the same as the battery PACK in the prior art, including a number of battery modules and a battery heating circuit, and a quick-plug connector interface is provided externally, and is connected to the domain control module 20 through the quick-plug connector 28 of the domain control module 20. The main circuits of the high-voltage part inside the domain control module 20 include: fuse F1 as the main fuse 26; main + relay K1 and main - relay K10 as the main relay 25; a battery heating control circuit including battery heating relays K5, K6 and battery heating fuses F2, F3; a soft start circuit connected in parallel with the main + relay K1, including a soft start resistor R1, a soft start relay K2 and a clamping diode D; a DC charging circuit connected to the battery PACK through the main fuse 26, including a positive charging contactor K7 and a negative charging contactor K8, and the other end of the DC charging circuit is connected to the external fast charging port (fast charging 300A); the main + relay After the relay K1 and the main relay K10, they are connected to the external drive motor connection port (motor 60 / 120kw) through the MCU, the AC charging port (OBC6.6kw) and the external DCDC output port (DCDC2.5kw) through the fuse F4 and the OBC / DCDC module, the external air conditioning power supply port (AC: 5KW) through the fuse F5, the external PTC power supply port (PTC1: 2.5kW; PTC2: 2.5kW) through the fuse F6 and the PTC heating contactors K11 and K12, and the external upper power supply port (upper: 10kw) through the fuse F7. Several voltage sampling points (U1, U2, U3, U4, U5, U00, U01, U02 and U04) are set in the circuit for detecting and judging the working status of the circuit.

[0029] The circuit of the commercial vehicle domain control battery pack in this embodiment integrates the high and low voltage parts at the front end of the battery PACK by integrating MCU high-voltage drive, OBC / DCDC drive, PTC, air conditioning, upper power supply, heating and other power distribution modules. The original light truck battery box MSD (power battery management system) is arranged on the front panel and shares space with high and low voltage connectors. The domain control module is responsible for the original MSD maintenance and high voltage disconnection and short circuit protection work, reducing product development costs.

[0030] The structural integration installation between the domain control module 20 and the battery PACK 10 includes the following methods: 1) If Figure 6As shown, the battery PACK10 removes the original BDU part and reserves an opening and space at the end for the insertion position 11 of the domain control module 20. The part of the domain control module 20 extending into the insertion position realizes the connection between the positive and negative busbars in the domain control and the positive and negative poles of the battery PACK through the connector. The end panel 12 at the corresponding end of the battery PACK10 adapts to the domain control module 20 as a sealing surface, and the sealing of the end face of the battery PACK10 is completed through the domain control module 20. Without changing the size and other structures of the battery PACK10, the domain control module 20 is fixed and sealed.

[0031] 2) As shown in FIG. 7 (a), FIG. 7 (b), and FIG. 7 (c), the battery PACK 10 extends out of the bell mouth 13, and a certain space is reserved. A sealing surface is used between the inside of the bell mouth 13 and the PACK surface, and a quick-plug connector is integrated for installation and use of the domain control module 20.

[0032] 3) As shown in Figures 8(a), 8(b) and 8(c), the bottom plate of the battery PACK10 extends out of the domain control bracket 14 and the domain control fixing point, the domain control module 20 and the battery PACK10 are independently sealed, and after being connected through the floating plug connector 15, the domain control module 20 is fixed on the domain control fixing point, and the PACK domain control bracket 14 is designed with a guide mechanism 16.

[0033] The solution of the present invention integrates multiple high and low voltage components into one component, with a more compact structure, optimized cost and weight, improved maintenance convenience, and a reduction of more than 50% in high voltage wiring harness and wiring harness length. It simplifies the layout, structure and wiring harness design of the whole vehicle; it can solve various problems caused by the separate design and layout of the three-electric system, such as complex structure, high cost, and heavy weight.

[0034] In terms of actual vehicle application, the solution of the present invention reduces the weight by 7kg through structural function reuse; after integration, there is only one component, which simplifies the installation process and reduces the steps of the vehicle installation process from 19 to 6, a simplification of 68%; after integration, there is only one component, which can also shorten the development and debugging time of the vehicle, reducing the development and debugging time from the original 30 days to 10 days.

[0035] Commercial vehicle example: A commercial vehicle of the present invention includes the domain control battery pack introduced in the battery pack embodiment, which improves the integration of the three-electric system of the commercial vehicle, reduces the weight and cost of the vehicle, and simplifies the vehicle assembly process.

Claims

1. A commercial vehicle domain control battery pack, characterized in that: It includes a battery PACK and a domain control module, the domain control module includes positive and negative busbars, and the positive and negative busbars are respectively connected to the positive and negative poles of the battery PACK through connectors; the domain control module is provided with a motor drive port for driving the motor, a fast charging port for DC charging, an AC charging port for AC charging, and a DC output port; the positive and negative busbars are connected to the motor drive port through a motor controller, connected to the fast charging port through a charging contactor, and connected to the AC charging port and the DC output port through OBC and DCDC respectively; the domain control module includes a domain control mainboard, and the domain control mainboard integrates BMS, VCU, BCM, OBC, DCDC, PDU, TMS, gateway and motor controller.

2. The commercial vehicle domain control battery pack according to claim 1, characterized in that: The domain control mainboard integrates the algorithms of BMS, VCU, BCM, OBC, DCDC, PDU, TMS, gateway and motor controller into one chip, and realizes chip computing power reuse through a circuit board; the hardware also integrates the power module, distribution module and drive module of BMS, VCU, BCM, OBC, DCDC, PDU, TMS, gateway and motor controller.

3. The commercial vehicle domain control battery pack according to claim 2, characterized in that: The domain control motherboard software part adopts the AutoSar tool chain for layered development, the upper application layer is isolated from the lower basic software, and uses standardized interactive interfaces and software component models.

4. The commercial vehicle domain control battery pack according to claim 1, characterized in that: The battery PACK leaves an opening and space at one end as the insertion position of the domain control module. The part of the domain control module extending into the insertion position realizes the connection between the positive and negative busbars and the positive and negative electrodes through a connector. The end panel at the corresponding end of the battery PACK serves as a sealing surface, which is sealed and fixedly connected to the domain control module to realize the sealing of the battery PACK.

5. The commercial vehicle domain control battery pack according to claim 1, characterized in that: The battery PACK extends out of the mounting bracket at one end, and the battery PACK and the domain control module are sealed independently. After the battery PACK and the domain control module are connected through a floating plug connector, the domain control module is fixed on the mounting bracket.

6. A commercial vehicle, characterized in that: It includes a domain control battery pack, which includes a battery PACK and a domain control module. The domain control module includes positive and negative bus bars, which are respectively connected to the positive and negative poles of the battery PACK through connectors; the domain control module is provided with a motor drive port for driving a motor, a fast charge port for DC charging, an AC charging port for AC charging, and a DC output port; the positive and negative bus bars are connected to the motor drive port through a motor controller, connected to the fast charge port through a charging contactor, and connected to the AC charging port and the DC output port through OBC and DCDC respectively; the domain control module includes a domain control mainboard, which integrates BMS, VCU, BCM, OBC, DCDC, PDU, TMS, gateway and motor controller.

7. The commercial vehicle according to claim 6, characterized in that: The domain control mainboard integrates the algorithms of BMS, VCU, BCM, OBC, DCDC, PDU, TMS, gateway and motor controller into one chip, and realizes chip computing power reuse through a circuit board; the hardware also integrates the power module, distribution module and drive module of BMS, VCU, BCM, OBC, DCDC, PDU, TMS, gateway and motor controller.

8. The commercial vehicle according to claim 7, characterized in that: The domain control motherboard software part adopts the AutoSar tool chain for layered development, the upper application layer is isolated from the lower basic software, and uses standardized interactive interfaces and software component models.

9. The commercial vehicle according to claim 6, characterized in that: The battery PACK leaves an opening and space at one end as the insertion position of the domain control module. The part of the domain control module extending into the insertion position realizes the connection between the positive and negative busbars and the positive and negative electrodes through a connector. The end panel at the corresponding end of the battery PACK serves as a sealing surface, which is sealed and fixedly connected to the domain control module to realize the sealing of the battery PACK.

10. The commercial vehicle according to claim 6, characterized in that: The battery PACK extends out of the mounting bracket at one end, and the battery PACK and the domain control module are sealed independently. After the battery PACK and the domain control module are connected through a floating plug connector, the domain control module is fixed on the mounting bracket.

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