Wireless bunching integrated intelligent battery distribution unit

Abstract

The invention discloses a wireless bunching integrated intelligent battery distribution unit. A battery pack circuit breaking unit and a battery management system are integrated, a conducting bar assembly is adopted to replace a traditional wire harness, the use amount of external wire harnesses is reduced by more than 80%, and a conducting bar and a relay are fixedly connected through an inner hexagonal combination bolt to form a stable conducting structure. The printed circuit board is in layered design, is electrically connected with the conducting bar through the connecting sheet and the terminal, and is welded by an SMT (Surface Mount Technology) technology, so that manual welding errors are eliminated. The shell is composed of an upper cover, an outer shell and a bottom plate, the upper cover and the outer shell are connected in a buckled mode, the outer shell and the bottom plate are fixed through screws, and a sealing rubber strip is arranged between the outer shell and the bottom plate for IP67-level protection. And radiating fins are arranged on the bottom plate. The IBDU is designed in a modularized manner, so that the BDU and the BMS are convenient to independently disassemble and maintain. The problems of complicated wiring harness, low reliability and the like of a traditional design are effectively solved, the electrical connection reliability, the production efficiency, the protection and heat dissipation performance and the maintenance convenience are improved, and the device is suitable for the fields of electric automobiles, energy storage systems and the like.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of automobile electronic and electrical manufacturing, and particularly relates to a wireless beam integrated intelligent battery distribution unit. BACKGROUND

[0002] In the field of modern electric vehicles and energy storage systems, the battery management system is crucial. The traditional battery distribution unit (BDU) and battery management system (BMS) have many drawbacks.

[0003] From the perspective of structural connection, in the traditional design, the BDU and BMS are mostly separated, and electrical connection is achieved through a large number of external wiring harnesses. The large number of wiring harnesses not only increases the complexity of the system, but also easily causes connection looseness, line aging and other fault hidden dangers, and occupies a large amount of installation space, which is not conducive to the compact design of the equipment. For example, in some early electric vehicle battery packs, the numerous wiring harnesses make the internal wiring messy, and it is extremely difficult to find fault points during later maintenance.

[0004] In terms of production and manufacturing, the traditional wiring harness connection relies on manual welding or assembly, which is low in efficiency and prone to welding errors, loose connections and other quality problems, making it difficult to meet the large-scale and high-quality production needs.

[0005] From the perspective of heat dissipation and protection, in the traditional design, the layout of various components is scattered, and the heat dissipation channel design is unreasonable, which is not conducive to the rapid dissipation of heat, affecting the stability and service life of key components such as relays and fuses. At the same time, the protection performance is limited, and it is difficult to meet the high-level waterproof and dustproof requirements, and in harsh environments, water vapor and dust can easily enter and cause faults.

[0006] In terms of maintenance convenience, the traditional separated structure requires complex operations when the BDU and BMS units are repaired and replaced, consuming a large amount of manpower and time cost, and reducing the availability and maintenance efficiency of the equipment.

[0007] With the development of electric vehicles and energy storage systems towards high integration, high reliability and intelligence, an innovative battery distribution unit solution is urgently needed to overcome the shortcomings of traditional designs, and a wireless beam integrated intelligent battery distribution unit (IBDU) has emerged. SUMMARY

[0008] Based on the above purpose, the present application provides a wireless beam integrated intelligent battery distribution unit

[0009] comprising:

[0010] an integrated module housing, the housing comprising an upper cover, an outer shell and a bottom plate, and internally integrated with a battery pack circuit breaking unit and a battery management system;

[0011] a conductive bar assembly containing a conductive bar, used to connect fuses, relays and shunts to achieve electrical connection;

[0012] The circuit board, i.e. PCB, is electrically connected with the conductive bar assembly through the connecting piece and the terminal, for collecting parameters and controlling the relay;

[0013] The connector is arranged outside the shell and is used for data and signal transmission with external devices.

[0014] Further, the conductive bar assembly is fixedly connected with the relay through the combination of the internal hexagonal bolt, forming an integrated conductive structure.

[0015] Further, the printed circuit board adopts a layered design, including a control layer for signal processing and a sensing layer for conductive bar parameter collection.

[0016] Further, the upper cover of the shell is quickly assembled with the shell through the buckle structure, and the shell is fixed with the bottom plate through the screw.

[0017] Further, the integrated module adopts a modular design, supporting independent disassembly and maintenance of the BDU and BMS units.

[0018] Further, the printed circuit board is directly welded on the conductive bar through the surface mount technology.

[0019] Further, a sealing rubber strip is arranged between the upper cover and the shell, forming a waterproof and dustproof structure.

[0020] Further, the bottom plate is provided with a heat dissipation fin for quickly leading away the heat generated by the relay and the fuse.

[0021] Preferably, the shell is integrally formed by using insulating engineering plastic, and an electromagnetic shielding layer is arranged inside

[0022] The beneficial effects of the present application are as follows:

[0023] The battery pack circuit breaking unit (BDU) and the battery management system (BMS) are integrated, which simplifies the system architecture, reduces the occupied space, and is beneficial to the miniaturization and compact design of the equipment; the conductive bar assembly is used to replace a large number of traditional wire harnesses, which reduces the use amount of external wire harnesses by more than 80%, reduces the connection failure risk, improves the electrical connection reliability, and at the same time makes the internal wiring simple, facilitating installation and later maintenance; the printed circuit board is directly welded on the conductive bar through the surface mount technology (SMT), avoiding the manual wire harness welding error, improving the production efficiency and product quality consistency, and being beneficial to large-scale standardized production.

[0024] The conductive row assembly is fixedly connected with the relay through the combination of the internal hex bolts, a stable integrated conductive structure is formed, the stability of the electrical connection is ensured, the sealing rubber strip is arranged between the upper cover and the shell, the IP67 level waterproof and dustproof standard is reached, the harsh environment can be effectively resisted, the invasion of water vapor and dust is prevented, the environmental adaptability and service life of the equipment are improved, the heat generated by the relay and the fuse is quickly led out, the heat management is optimized, the stable operation of the key components at the appropriate temperature is ensured, and the system reliability is improved.

[0025] The modular design supports independent disassembly and maintenance of the BDU and the BMS unit, greatly reduces the maintenance difficulty and time cost, and improves the equipment availability and maintenance efficiency. BRIEF DESCRIPTION OF DRAWINGS

[0026] In order to more clearly illustrate the technical solutions in the present application or prior art, the drawings needed to be used in the following embodiments or prior art description will be briefly introduced. Obviously, the drawings in the following description are only the present application, and other drawings can be obtained by those skilled in the art without creative labor.

[0027] Figure 1 It is a schematic diagram of the overall structure of the battery distribution unit of the embodiment of the present application.

[0028] Figure 2 It is a schematic diagram of the top view structure of the embodiment of the present application with a circuit board.

[0029] Figure 3 It is a schematic diagram of the bottom view structure of the embodiment of the present application with a circuit board.

[0030] Figure 4 It is a schematic diagram of the top view structure of the embodiment of the present application without a circuit board.

[0031] Figure 5 It is a schematic diagram of the bottom view structure of the embodiment of the present application without a circuit board.

[0032] In the figure: 1, upper cover; 2, relay; 3, conductive row; 4, fuse; 5, shell; 6, connecting piece; 7, terminal; 8, circuit board; 9, bottom plate; 10, screw; 11, shunt; 12, connector; 13, combination of internal hex bolts. DETAILED DESCRIPTION

[0033] The present application will be described in detail below in combination with the drawings and specific embodiments. It should be noted here that in order to make the embodiments more detailed, the following embodiments are the best and preferred embodiments, and other alternative ways can also be used by those skilled in the art to implement some known technologies; and the drawings are only used to more specifically describe the embodiments, and are not intended to specifically limit the present application.

[0034] It is noted that the use of "one embodiment," "an embodiment," "certain embodiments," "some embodiments," etc., in the specification does not necessarily refer to the same embodiment, although it may. In addition, the description is not limited to a single embodiment, but can include many alternative embodiments. In addition, the use of "a" or "an" in the description indicates that there are one or more of the referenced features or components. For example, "a" or "an" indicates that there is at least one, but there can be more than one.

[0035] In general, the terminology can be understood at least in part from a context of a use of the terminology. For example, the term "one or more" as used herein, depending at least in part upon a context of a use of the term, can be used to describe any feature, structure, or characteristic in a singular sense or can be used to describe combinations of features, structures, or characteristics in a plural sense. Similarly, the term "based on" can be understood as not necessarily intended to convey an exclusive set of factors and can instead allow for existence of additional factors not necessarily expressly described, again, at least in part, depending at least in part on a context in which the term is used.

[0036] Referring to Figures 1 to 5

[0037] A wireless beam integrated intelligent battery distribution unit, comprising:

[0038] An integrated module housing, the housing comprising an upper cover 1, an outer shell 5 and a bottom plate 9, internally integrated with a battery pack circuit breaking unit and a battery management system;

[0039] A conductive bar assembly, comprising a conductive bar 3, for connecting a fuse 4, a relay 2 and a shunt 11 to realize electrical connection;

[0040] A circuit board 8, i.e. a PCB printed circuit board, electrically connected with the conductive bar assembly through a connecting sheet 6 and a terminal 7, for collecting parameters and controlling the relay 2;

[0041] A connector 12, provided outside the housing, for data and signal transmission with external devices.

[0042] Specifically, the conductive bar assembly is fixedly connected with the relay 2 through an internal hexagonal combination bolt 13, forming an integrated conductive structure, the printed circuit board adopts a layered design, comprising a control layer for signal processing and a sensing layer for parameter collection of the conductive bar 3, the upper cover 1 and the outer shell 5 of the housing are quickly assembled through a buckle structure, the outer shell 5 is fixed with the bottom plate 9 through a screw 10, the integrated module adopts a modular design, supporting independent disassembly and maintenance of the BDU and the BMS unit, the printed circuit board is directly welded on the conductive bar 3 through a surface mounting technology, a sealing rubber strip is arranged between the upper cover 1 and the outer shell 5, forming a waterproof and dustproof structure, the bottom plate 9 is provided with a heat dissipation fin for quickly leading away heat generated by the relay 2 and the fuse 4, the housing is integrally formed by using insulating engineering plastic, and an electromagnetic shielding layer is arranged inside.

[0043] Shell assembly: The shell of the wireless beam integrated intelligent battery distribution unit IBDU is composed of an upper cover 1, an outer shell 5, and a bottom plate 9. The upper cover 1 and the outer shell 5 are quickly assembled through a buckle structure, which facilitates quick assembly and ensures a certain sealing performance; the outer shell 5 and the bottom plate 9 are fixed through screws 10 to ensure the stability of the overall structure. A sealing rubber strip is installed between the upper cover 1 and the outer shell 5 to achieve IP67 level waterproof and dustproof standard, effectively protecting the internal components from the external environment.

[0044] Internal component installation: In the shell, first install key components such as relays 2, fuses 4, and shunts 11. The conductive bar 3 is connected to the components such as relays 2 through a combination of hexagonal bolts 13, forming an integrated conductive structure, replacing the traditional wire harness connection method, and reducing the use of external wire harness by more than 80%.

[0045] Circuit board connection: The printed circuit board - circuit board 8 adopts a layered design, including a control layer and a sensing layer. The circuit board 8 is electrically connected to the conductive bar 3 through the connecting piece 6 and the terminal 7, where the sensing layer is used to collect parameters of the conductive bar 3 and other components, and the control layer is used for signal processing and controlling the working state of the relays 2 and other components. The circuit board 8 is directly soldered to the conductive bar 3 through surface mount technology SMT, ensuring the accuracy and stability of electrical connection and eliminating manual wire harness welding errors.

[0046] External connection setting: Connectors 12 are provided on the outside of the shell for data and signal transmission with external devices, realizing communication between the IBDU and the vehicle control system or other external equipment.

[0047] Working principle

[0048] Electrical connection and current distribution: When the system is powered on, the current is distributed and transmitted among the fuses 4, relays 2, and shunts 11 through the conductive bar 3. The fuse 4 plays a role in overcurrent protection, automatically fusing and cutting off the circuit when the current exceeds the rated value, protecting the downstream equipment; the relay 2 controls the on and off of the circuit according to the control signal of the battery management system BMS, to control the charging and discharging process of the battery pack, etc.; the shunt 11 is used to accurately measure the current size and feedback the current signal to the BMS.

[0049] Parameter acquisition and control: The sensing layer of the printed circuit board real-time acquires the voltage, current and other parameters of the conductive row 3, and the working state information of the relay 2, the fuse 4 and other components, and transmits these information to the control layer. The control layer processes and analyzes the collected data, judges whether the system is running normally according to the preset logic and algorithm. If abnormal conditions such as overcurrent, overvoltage and the like are detected, the control layer will send a control signal to the relay 2 to make it act to cut off the circuit, ensuring the safety of the system. At the same time, the control layer will also transmit relevant data to external equipment such as the vehicle controller through the connector 12 for more comprehensive monitoring and management.

[0050] The present application encompasses any alternatives, modifications, equivalent methods and solutions made to the essence and scope of the present application. In order for the public to have a thorough understanding of the present application, specific details are described in the following preferred embodiments of the present application, and the present application can also be fully understood without the description of these details to those skilled in the art. In addition, in order to avoid unnecessary confusion to the essence of the present application, well-known methods, processes, procedures, elements and circuits, etc. are not described in detail.

[0051] The above is only the preferred embodiment of the present application, and it should be pointed out that for ordinary skilled in the art, without departing from the principles of the present application, a number of improvements and refinements can also be made, which should be considered as the protection scope of the present application.

Claims

1. A wireless beamforming integrated smart battery distribution unit, characterized by, The application relates to an integrated module for battery management unit (BMS) and battery disconnect unit (BDU), which comprises: An integrated module housing, which comprises an upper cover (1), an outer shell (5) and a bottom plate (9), and is internally integrated with a battery pack circuit breaking unit and a battery management system; A conductive bar assembly, which comprises a conductive bar (3) and is used for connecting a fuse (4), a relay (2) and a shunt (11) to realize electrical connection; A circuit board (8), namely a PCB printed circuit board, which is electrically connected with the conductive bar assembly through a connecting sheet (6) and a terminal (7) and is used for collecting parameters and controlling the relay (2); A connector (12) arranged outside the housing and used for data and signal transmission with external devices.

2. The wireless beamed integrated smart battery distribution unit of claim 1, wherein: The conductive bar assembly is fixedly connected with the relay (2) through an inner hexagonal combined bolt (13) to form an integrated conductive structure.

3. The wireless beamed integrated smart battery distribution unit of claim 1, wherein: The printed circuit board adopts a layered design and comprises a control layer used for signal processing and a sensing layer used for collecting parameters of the conductive bar (3).

4. The wireless beamed integrated smart battery distribution unit of claim 1, wherein: The upper cover (1) of the housing is quickly assembled with the outer shell (5) through a buckle structure, and the outer shell (5) is fixed with the bottom plate (9) through a screw (10).

5. The wireless beamed integrated smart battery distribution unit of claim 1, wherein: The integrated module adopts a modular design and supports independent disassembly and maintenance of the BDU and the BMS unit.

6. The wireless beamed integrated smart battery distribution unit of claim 1, wherein: The printed circuit board is directly welded on the conductive bar (3) through a surface mounting technology.

7. The wireless beamed integrated smart battery distribution unit of claim 4, wherein: A sealing rubber strip is arranged between the upper cover (1) and the outer shell (5) to form a waterproof and dustproof structure.

8. The wireless beamed integrated smart battery distribution unit of claim 1, wherein: The bottom plate (9) is provided with heat dissipation fins for quickly leading away heat generated by the relay (2) and the fuse (4).

9. The wireless beamed integrated smart battery distribution unit of claim 1, wherein: The housing is integrally formed by using insulating engineering plastic and is internally provided with an electromagnetic shielding layer.

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