Power distribution circuit board and PDU power distribution circuit of electric vehicle and electric ship

Abstract

The invention discloses a power distribution circuit board and a PDU power distribution circuit for an electric vehicle and an electric ship, and the circuit board comprises a circuit board which is of a printed circuit board structure, and is provided with a plurality of components for achieving a power distribution function and a plurality of connecting copper bars for achieving the electric connection between the components; compared with the prior art, the power distribution circuit board structure has the advantages that the mounting work of the components can be realized through machine operation (SMT (Surface Mount Technology) mounting and over-wave soldering), excessive manual participation is not needed, the product consistency can be ensured, the production efficiency is improved, and the production cost is reduced. And the arrangement distance between the components can be more compact, so that the overall layout is more regular and reasonable, materials and labor can be effectively saved, and the overall structure and the process cost have more advantages.

Description

Technical Field

[0001] The present invention belongs to the technical field of PDU power distribution for electric vehicles, and relates to a power distribution circuit board and a PDU power distribution circuit for electric vehicles and electric ships. Background Art

[0002] In the development process of electric vehicles, the power distribution unit (PDU) power distribution cabinet shoulders the important task of accurately distributing the battery electric energy to each electrical system of the vehicle, covering the motor drive system, the charging system, and the heating system, etc. However, there are many drawbacks in the existing PDU power distribution cabinets:

[0003] 1. When large current is switched on and off, the energy loss is large, the heat generation is serious, and the contacts are easily damaged, resulting in a great reduction in the reliability of the connection between the motor circuit and the battery.

[0004] 2. The communication method and control logic are not accurate enough, making it difficult to achieve stable and efficient control during the vehicle startup and charging processes.

[0005] 3. The detection of voltage, current, and temperature lacks comprehensiveness and accuracy, and cannot timely transmit reliable data to the protection circuit. Summary of the Invention

[0006] In order to solve the above technical problems, the present invention adopts the following technical solutions:

[0007] A power distribution circuit board for electric vehicles and electric ships, comprising: a circuit board, the circuit board adopts a printed circuit board structure, and a plurality of components for realizing power distribution functions and connection copper bars for realizing electrical connection work between each component are arranged on the circuit board;

[0008] Both the components and the connection copper bars are arranged on the circuit board by means of surface mounting. The components on the circuit board include but are not limited to: a main positive relay, a pre-charge relay, and a pre-charge resistor; the relay control lines and the circuit total voltage acquisition part are routed on the circuit board and led to corresponding positions.

[0009] A PDU power distribution circuit for electric vehicles and electric ships, comprising:

[0010] Main circuit: The main circuit of the present invention is scientifically and reasonably designed. The positive terminal of the battery is sequentially connected to the main positive relay (rated current 150A), the pre-charge relay (rated current 20A), and the pre-charge resistor (60W 40Ω), and the negative terminal of the battery is connected to the main negative relay (rated current 150A). The motor circuit is connected to the battery through the main positive and main negative relays, and the fuse parameter is 62.5A to ensure the stable current of the motor during operation and prevent overload. The heating circuit is controlled by a heating relay (rated current 20A), and the fuse current is 2A to ensure the stable operation of the heating system. A shunt (150A 50mA 0.5%) is set in the main circuit for accurate current detection, and a pre-charge detection circuit is also provided to monitor the pre-charge process to ensure the stability and safety of pre-charging.

[0011] Control circuit: The control circuit is connected to the vehicle controller and the BCU main control through CAN communication to achieve precise control of the contactors. When the vehicle starts, the BCU main control first controls the pre-charge relay to close for pre-charging. When the pre-charge detection circuit detects that the pre-charge voltage reaches the set value, it then controls the main positive and main negative relays to close to achieve a smooth start and avoid damage to the circuit and battery caused by current impact. During the charging process, the BCU main control controls the on / off of the fast-charge relay and adjusts the charging current according to the instructions of the battery management system to ensure the efficiency and safety of the charging process. The relay control plug uses the socket AP2502810P and the plug Y2502810 of the Weifei brand, and their pin connection relationships are clear to ensure the accurate transmission of control signals.

[0012] Detection circuit: The detection circuit monitors the voltage, current, and temperature of the main circuit through a voltage detection module, a shunt, and temperature sensors distributed at key positions in the power distribution cabinet. The voltage detection module can accurately detect the voltage change in the main circuit, the shunt is used to accurately measure the current magnitude, and the temperature sensors sense the temperature in the power distribution cabinet in real time to provide comprehensive data support for the stable operation of the system.

[0013] Protection circuit: The protection circuit provides comprehensive protection against overcurrent, overvoltage, and overheating conditions in each circuit by means of fuses, controlling the disconnection of relays, and starting heat dissipation or reducing power output. When the current exceeds the set value, the fuse quickly cuts off the circuit to prevent components from being damaged due to overcurrent. When the voltage exceeds the set range, the corresponding relay is controlled to disconnect to avoid damage to circuit components caused by overvoltage. When the temperature exceeds the set threshold, the heat dissipation fan is started or measures to reduce power output are taken to ensure that the equipment operates within a safe temperature range. The set values of current, voltage, and temperature are determined according to the actual operating requirements of the electric vehicle and the safe operating range of components.

[0014] Circuit board: The circuit board is provided with ports connected to each circuit, a relay control interface, and a detection interface. Each relay is installed on the circuit board, and its position and connection relationship conform to the circuit function logic. A heating fuse is set, and its position is related to the heating circuit. The layout and wiring method of the circuit board are carefully designed to achieve efficient circuit connection and good electromagnetic compatibility, reduce electromagnetic interference, and improve the stability and reliability of the system.

[0015] Advantages of the present invention:

[0016] Compared with the prior art, in the distribution circuit board structure of the present invention, the installation work of components can be realized through machine operation (SMT patching, wave soldering), without much manual participation, which can ensure product consistency. Moreover, the layout distance between components can be more compact, making the overall layout more regular and reasonable, effectively saving materials and labor, and making the overall structure and process cost more advantageous.

[0017] Through innovative design, the PDU power distribution circuit realizes that the control circuit uses CAN communication and precise logic, and is paired with a specific relay control plug-in and pin connection to achieve accurate transmission of control signals, ensuring smooth and efficient vehicle start-up and charging. The detection and protection circuits work together. The former comprehensively monitors voltage, current, and temperature and provides reliable data for the latter. Once an abnormality is detected, the protection circuit responds quickly to effectively protect components and improve vehicle safety. In addition, through reasonable layout and wiring of the circuit board, efficient connection and good electromagnetic compatibility are achieved, reducing signal interference and energy loss, enhancing the performance and stability of the power distribution cabinet, extending the service life of the equipment, and reducing maintenance costs and replacement frequencies. Description of the drawings

[0018] Figure 1 It is a schematic structural diagram of the distribution circuit board of the present invention.

[0019] Figure 2 It is a schematic diagram of the connection of circuit modules of the present invention.

[0020] Figure 3 It is a schematic electrical principle diagram of the main circuit in the present invention. Detailed implementation manners

[0021] Next, the technical solutions in the embodiments of the present application will be clearly and completely described in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. It should be understood that the present application is not limited by the example embodiments disclosed herein. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present application.

[0022] In the description of the present invention, it should be understood that the orientation or positional relationship indicated by the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. is based on the orientation or positional relationship shown in the drawings, and is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus should not be construed as a limitation to the present invention.

[0023] In addition, the terms "first" and "second" are only used for descriptive purposes and should not be construed as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. Thus, the features defined with "first" and "second" may explicitly or implicitly include one or more of such features. In the description of the present invention, the meaning of "a plurality of" is two or more, unless otherwise specifically defined.

[0024] In the embodiments of the present invention, unless otherwise clearly specified and limited, the terms "installation", "connection", "connection", "fixation", etc. should be understood in a broad sense. For example, it may be a fixed connection, a detachable connection, or integrated; it may be a mechanical connection or an electrical connection; it may be directly connected or indirectly connected through an intermediate medium, and it may be the communication inside two elements or the interaction relationship between two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0025] Please refer to Figure 1 , a power distribution circuit board for an electric vehicle and an electric ship, comprising: a circuit board 5, the circuit board 5 adopting a printed circuit board structure, on which a plurality of components 6 for realizing power distribution functions and connection copper bars 7 for realizing the electrical connection work between the components 6 are provided;

[0026] Both the components 6 and the connection copper bars 7 are arranged on the circuit board 5 by means of surface mounting. The components 6 on the circuit board 5 include but are not limited to: a main positive relay, a pre-charge relay, and a pre-charge resistor; the relay control lines and the circuit total voltage acquisition part are routed on the circuit board 5 and led to corresponding positions; such a structural arrangement method saves the time for manual screwing fixation, can ensure product consistency, and the arrangement distance between the components 6 can be more compact, making the overall layout more regular and reasonable, effectively saving materials and labor, and making the overall structure and process cost more advantageous.

[0027] Further, a plurality of pads for arranging components 6 are preset on the circuit board 5, and each component 6 is fixedly arranged at the corresponding pad position; such an arrangement can reduce the processing difficulty of the patch processing of the component 6 and the connecting copper row 7, and effectively improve the overall processing efficiency.

[0028] Please refer to Figures 2 to 3 , the present invention also provides a PDU power distribution circuit for electric vehicles and electric ships, including: Main circuit 1: When actually installing the main circuit,

[0029] Select according to the working requirements: main positive relay (rated current 150A), pre-charge relay (rated current 20A), main negative relay (rated current 150A), fast charge relay (rated current 100A) and heating relay (rated current 20A).

[0030] Among them, the main positive and main negative relays adopt silver alloy contacts, which can effectively reduce energy loss and heat generation during large current on-off, and have high arc resistance performance.

[0031] The pre-charge resistor (60W 40Ω) can effectively limit the excessive current during the pre-charge process, and at the same time ensure that it will not be damaged due to overheating.

[0032] The motor circuit fuse selects a fast-blowing fuse with a rated current of 150A, and the heating circuit fuse selects a fuse element with a rated current of 2A. When an abnormal situation such as overload or short circuit occurs in the circuit, the fuse can quickly cut off the circuit to protect the components in the corresponding circuit safely.

[0033] The shunt (150A 50mA 0.5%) is installed close to the current measurement point of the main circuit 1 to ensure that the current magnitude can be accurately detected and the signal is transmitted to the detection circuit 3 and the protection circuit 4.

[0034] Control circuit 2: The CAN communication connection of the control circuit 2 is realized by selecting a suitable CAN transceiver chip, which can stably realize the data transmission between the vehicle controller and the BCU main control. During the vehicle startup process, the BCU main control controls the pre-charge relay to close first according to the preset control logic to start the pre-charge process.

[0035] At the same time, the pre-charge detection circuit 3 monitors the pre-charge voltage in real time. When the pre-charge voltage reaches the set value, the BCU main control then controls the main positive and main negative relays to close to realize the smooth startup of the vehicle. During the charging process, the BCU main control ensures that the battery can be charged safely and efficiently by controlling the on-off of the fast charge relay and adjusting the charging current magnitude according to the instructions sent by the battery management system.

[0036] The relay control plug-in uses the socket AP2502810P and the plug Y2502810 of the Weifei brand. Their pin connection relationships are clear, ensuring the accurate transmission of control signals.

[0037] Among them, as Figure 2 shown, the pin connections of the relay control plug-in are as follows:

[0038] Pin 1 (RL2 - Precharge relay control negative) is connected to the control negative terminal of the precharge relay, used to receive control signals to control the opening and closing of the precharge relay.

[0039] Pin 2 (RL2 + Precharge relay control positive) is connected to the control positive terminal of the precharge relay, providing positive power for the control circuit 2 of the precharge relay.

[0040] Pin 3 (RL1 + Main negative relay control positive) is connected to the control positive terminal of the main negative relay, providing positive power for the control circuit 2 of the main negative relay.

[0041] Pin 4 (RL1 - Main negative relay control negative) is connected to the control negative terminal of the main negative relay, used to receive control signals to control the opening and closing of the main negative relay.

[0042] Pin 5 (RL3 - Fast charge relay control negative) is connected to the control negative terminal of the fast charge relay, used to receive control signals to control the opening and closing of the fast charge relay.

[0043] Pin 6 (RL3 + Fast charge relay control positive) is connected to the control positive terminal of the fast charge relay, providing positive power for the control circuit 2 of the fast charge relay.

[0044] Pin 7 (RL4 - Heating relay control negative) is connected to the control negative terminal of the heating relay, used to receive control signals to control the opening and closing of the heating relay.

[0045] Pin 8 (RL4 + Heating relay control positive) is connected to the control positive terminal of the heating relay, providing positive power for the control circuit 2 of the heating relay.

[0046] Pin 9 (RL5 + Main positive relay control positive) is connected to the control positive terminal of the main positive relay, providing positive power for the control circuit 2 of the main positive relay.

[0047] Pin 10 (RL4 - Main positive relay control negative) is connected to the control negative terminal of the main positive relay, used to receive control signals to control the opening and closing of the main positive relay.

[0048] Detection Circuit 3: The voltage detection module in Detection Circuit 3 selects a specific model with high precision and stability, and can accurately monitor the voltages of each key node in Main Circuit 1. The installation position of the voltage detection module is close to the key node to be detected, and reasonable wiring is adopted to ensure the accuracy of signal transmission. Current detection is achieved through a shunt, and the accuracy and response speed of the shunt meet the detection requirements. Temperature detection uses temperature sensors distributed at key parts inside the power distribution cabinet, and these temperature sensors can sense the temperature changes inside the power distribution cabinet in real time.

[0049] Protection Circuit 4: Overcurrent protection of Protection Circuit 4 is achieved through a fast-fusing fuse. When the current detection module detects that the current exceeds the set value, the fuse can quickly cut off the circuit within an extremely short time to protect the components of Protection Circuit 4. Overvoltage protection is achieved by controlling the corresponding relay to disconnect. When the voltage detection module monitors that the voltage exceeds the set range, Protection Circuit 4 immediately controls the relay to disconnect to avoid damage to circuit components caused by overvoltage.

[0050] Circuit Board: The circuit board is made of high-quality materials and advanced manufacturing processes to ensure that its electrical and mechanical properties meet the requirements. In the layout design of the circuit board, the functions and connection relationships of each component are fully considered, and the ports connected to each circuit, the relay control interface, and the detection interface are reasonably distributed on the circuit board to facilitate the connection of external circuits and the transmission of internal signals.

[0051] It should also be noted that in this article, relational terms such as first and second are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the term "comprising", "including" or any other variant thereof is intended to cover non-exclusive inclusion, so that a process, method, article or device comprising a series of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article or device. Without further limitation, an element defined by the statement "comprising a..." does not exclude the existence of additional identical elements in the process, method, article or device comprising the element.

[0052] The above description of the disclosed embodiments enables those skilled in the art to implement or use the present application. Various modifications to these embodiments will be obvious to those skilled in the art, and the general principles defined herein can be implemented in other embodiments without departing from the spirit or scope of the present application. Therefore, the present application will not be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A power distribution circuit board for an electric vehicle and an electric ship, characterized in that: include: The circuit board adopts a printed circuit board structure, and is provided with a plurality of components for realizing the power distribution function and connecting copper bars for realizing the electrical connection between the components; The components and connecting copper bars are arranged on the circuit board by means of patches. The components on the circuit board include but are not limited to: main positive relay, pre-charge relay and pre-charge resistor; the relay control line and the circuit total voltage collection part are routed on the circuit board and led to the corresponding position.

2. A power distribution circuit board for an electric vehicle and an electric ship according to claim 1, characterized in that: A plurality of pads are preset on the circuit board for realizing component arrangement, and each component is fixedly arranged at a corresponding pad position.

3. A PDU power distribution circuit for electric vehicles and electric ships, characterized in that: include: Main circuit, the positive end of the battery in the main circuit is connected to the main positive relay, the pre-charge relay and the pre-charge resistor in sequence, and the negative end of the battery is connected to the main negative relay; the motor circuit is connected to the battery through the main positive and main negative relays; the fast charging circuit is connected to the battery through the fast charging relay; the heating circuit is controlled by the heating relay; A shunt is provided in the main circuit for current detection, and a pre-charge detection circuit is provided to monitor the pre-charge process; The control circuit connects the vehicle controller and the BCU main control through CAN communication to realize the control of each group of relays; The detection circuit monitors the voltage, current and temperature of the main circuit through the voltage detection module, shunt and temperature sensors distributed in key positions in the power distribution cabinet, providing data support for the stable operation of the system; Protection circuit, for over-current, over-voltage and over-heating of each circuit, circuit protection is achieved by disconnecting fuses and control relays and starting heat dissipation or reducing power output; The circuit board is provided with ports connected to various circuits, a relay control interface and a detection interface.

4. A PDU power distribution circuit for electric vehicles and electric ships according to claim 3, characterized in that: The main positive and main negative relays use silver alloy contacts to reduce energy loss and heat generation when large currents are switched on and off, and have high arc resistance, thereby ensuring the reliability and stability of the motor circuit and battery connection.

5. A PDU power distribution circuit for electric vehicles and electric ships according to claim 3, characterized in that: The pre-charging and heating relays are selected according to the rated current of 20A. They can stably close and disconnect at this current and have a certain overload capacity to ensure the stability of the pre-charging and heating control process.

6. According to the PDU power distribution circuit for electric vehicles and electric ships of claim 5, the pre-charging resistor has a power of 60W and a resistance of 40Ω, which can limit the current during pre-charging and is not easily damaged by overheating.

7. A PDU power distribution circuit for electric vehicles and electric ships according to claim 5, characterized in that: The motor circuit is equipped with a fast-blow fuse with a rated current of 150A, and the heating circuit is equipped with a fuse element with a rated current of 2A. When abnormal conditions such as overload or short circuit occur in the corresponding circuit, the circuit can be quickly cut off to protect the circuit components.

8. A PDU power distribution circuit for electric vehicles and electric ships according to claim 3, characterized in that: During vehicle starting and charging, the control circuit controls the action of each relay according to the established logic to achieve smooth vehicle starting and efficient and safe charging.

9. A PDU power distribution circuit for electric vehicles and electric ships according to claim 3, characterized in that: The detection circuit realizes comprehensive monitoring of the voltage, current and temperature of the main circuit through different detection components.

10. A PDU power distribution circuit for electric vehicles and electric ships according to claim 3, characterized in that: When the current, voltage, or temperature are abnormal, the protection circuit takes appropriate measures to ensure that the equipment operates within a safe range.

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