Vehicle high-voltage power distribution unit

Abstract

A vehicle high-voltage power distribution unit relates to the technical field of electric vehicle power distribution. The vehicle high-voltage power distribution unit comprises a base, a PCB, a relay, a low-voltage plug-in, a high-voltage plug-in and a fuse. The base is provided with a containing cavity, low-pressure mounting holes and high-pressure mounting holes which are communicated with the containing cavity are formed in the side wall of the base, and the low-pressure mounting holes and the high-pressure mounting holes are distributed at intervals; the PCB is arranged in the accommodating cavity of the base, and a circuit is printed on the PCB; the relay is arranged on the PCB, and a control circuit of the relay is connected with a circuit on the PCB; the low-voltage plug-in is arranged at the low-voltage mounting hole, the low-voltage plug-in is communicated with a circuit on the PCB, the low-voltage plug-in is communicated with a control circuit of the relay, and the low-voltage plug-in is used for being connected with a power supply and a control terminal; the high-voltage plug-in is arranged in the high-voltage mounting hole, is communicated with an execution circuit on the relay, and is used for accessing a high-voltage power supply and a high-voltage load; and the fuse is arranged between the high-voltage plug-in and the relay.

Description

Technical Field

[0001] This application relates to the field of electric vehicle power distribution technology, and in particular to a high-voltage power distribution unit for vehicles. Background Technology

[0002] Both vehicle battery packs and energy storage battery packs involve charging and power distribution systems. Due to different application scenarios and electrical architectures, the design schemes for these systems vary. Vehicle power distribution modules utilize BDU integrated modules, but these modules require customized development, resulting in poor product versatility. Furthermore, the internal component connections and copper busbar wiring with external components all require bolt fixation, leading to high reliance on manual operation and low product consistency and reliability. Summary of the Invention

[0003] This application provides a vehicle high-voltage power distribution unit to solve the above-mentioned problems.

[0004] This application provides a vehicle high-voltage power distribution unit, including a base, a PCB board, a relay, a low-voltage plug-in, a high-voltage plug-in, and a fuse. The base has a receiving cavity, and low-voltage mounting holes and high-voltage mounting holes communicating with the receiving cavity are formed on the side wall of the base, with the low-voltage mounting holes and high-voltage mounting holes spaced apart. The PCB board is disposed in the receiving cavity of the base, and circuits are printed on the PCB board. The relay is disposed on the PCB board, and the control circuit of the relay is connected to the circuit on the PCB board. The low-voltage plug-in is disposed at the low-voltage mounting hole, and the low-voltage plug-in is connected to the circuit on the PCB board and the control circuit of the relay. The low-voltage plug-in is used to connect to a power supply and a control terminal. The high-voltage plug-in is disposed in the high-voltage mounting hole, and the high-voltage plug-in is connected to the execution circuit on the relay. The high-voltage plug-in is used to connect to a high-voltage power supply and a high-voltage load. The fuse is disposed between the high-voltage plug-in and the relay.

[0005] The vehicle high-voltage power distribution unit provided in this application includes a base, a PCB board, relays, low-voltage plug-in, high-voltage plug-in, and fuses. The PCB board, relays, and other components are directly mounted through the receiving cavity of the base, reducing the space occupied by scattered components and improving the overall structural compactness. The spacing between the low-voltage mounting holes and the high-voltage mounting holes can avoid electromagnetic interference between the low-voltage control circuit and the high-voltage power circuit, reduce the risk of short circuits or signal interference, and ensure circuit safety.

[0006] The fuse is connected in series between the high-voltage plug and the relay. When a short circuit or overload occurs in the high-voltage circuit, the fuse melts and cuts off the circuit, preventing damage to the relay and high-voltage loads (such as motors and batteries). The connection between the low-voltage plug and the relay control circuit, and the connection between the high-voltage plug and the relay execution circuit, can meet the vehicle's power distribution needs.

[0007] The base shape in this structure is easy to design and can be adjusted as needed. The internal relays can also be replaced with different models as required. The design is convenient and versatile. The connection between the components on the PCB board inside the base is simple. There is no need to configure copper busbars. The required circuit connection can be achieved directly through the printed circuit and wiring on the PCB board, reducing manual operation and improving product consistency and safety.

[0008] In some embodiments of this application, the vehicle high-voltage power distribution unit further includes a temperature sensor, which is mounted on a PCB board and electrically connected to a low-voltage connector via the PCB board.

[0009] Temperature sensors can directly detect the temperature of the PCB board, relays, and fuses. The temperature is fed back to the control terminal through the PCB board circuit and low-voltage plug-in, enabling dynamic monitoring of the temperature in key areas inside the power distribution unit. Temperature signals can detect potential relay faults in advance by detecting temperature changes, thus improving relay safety.

[0010] In some embodiments of this application, the relay, fuse, and temperature sensor are all soldered onto the PCB board. Soldering ensures a stable connection between the relay, fuse, and temperature sensor and the PCB board, and compared to bolted connections, it reduces manual operation, improves reliability and consistency; furthermore, soldering saves space and facilitates spatial design.

[0011] In some embodiments of this application, the vehicle high-voltage power distribution unit further includes a threaded connector, and the PCB board and the base are fixedly connected by the threaded connector.

[0012] The threaded connection has high strength and can firmly fix the PCB board in the base cavity to resist vehicle vibration; the threaded connector is detachable, which facilitates the assembly, inspection or replacement of the PCB board; the threaded connector is equipped with an insulating bushing to further achieve electrical insulation between the PCB board and the base.

[0013] In some embodiments of this application, the vehicle high-voltage power distribution unit further includes a top cover, which covers the opening of the base receiving cavity.

[0014] The top cover seals the cavity, preventing external contaminants such as dust, moisture, and oil from entering and protecting internal precision components such as PCB boards, relays, and fuses from short circuits and insulation aging caused by contaminants.

[0015] In some embodiments of this application, a mounting protrusion is formed at the end of the base away from the top cover. The mounting protrusion is used for fixed connection with the area to be installed. The mounting protrusion can cooperate with the positioning structure of the area to be installed on the vehicle body for quick positioning and to ensure the strength and reliability of the connection; at the same time, the mounting protrusion can be adapted to different vehicle needs and has strong versatility.

[0016] In some embodiments of this application, the circuit on the PCB board is configured as multiple circuits, which are used to control the control circuit of the relay and to collect the temperature signal of the temperature sensor.

[0017] The relay control circuit and the temperature sensor acquisition circuit are physically isolated to avoid electromagnetic interference between strong and weak electrical signals, ensuring the accuracy of temperature acquisition and the stability of relay control; multiple independent circuits can be optimized separately to adapt to the transmission requirements of different signals.

[0018] In some embodiments of this application, the low-voltage mounting hole and the high-voltage mounting hole are located on the same side wall of the base. This same-side layout reduces the area occupied by the base side wall, making the overall power distribution unit more compact and adaptable to the limited installation space in a vehicle.

[0019] In some embodiments of this application, a high-voltage wiring harness is configured on the high-voltage plug-in, which is used to connect the relay's execution circuit. The high-voltage wiring harness uses high-voltage and high-current resistant insulating materials and conductive cores to meet the insulation requirements and current-carrying requirements of the vehicle's high-voltage circuit. Attached Figure Description

[0020] The accompanying drawings are provided to further understand the technical solutions of the present invention and constitute a part of the specification. They are used together with the embodiments of this application to explain the technical solutions of the present invention and do not constitute a limitation on the technical solutions of the present invention.

[0021] Figure 1 This is an exploded schematic diagram of a vehicle high-voltage power distribution unit provided in an embodiment of this application.

[0022] Figure 2 This is a three-dimensional schematic diagram of a vehicle high-voltage power distribution unit after the top cover has been removed, as provided in an embodiment of this application.

[0023] Figure 3 This is a schematic diagram of a vehicle high-voltage power distribution unit provided in an embodiment of this application.

[0024] Figure 4 This is a top view of a PCB board inside a vehicle high-voltage power distribution unit, provided as an embodiment of this application.

[0025] Figure 5 This is a schematic diagram of the circuit connection relationship of a vehicle high-voltage power distribution unit provided in an embodiment of this application.

[0026] Reference numerals: 1-Base; 101-Receiving cavity; 102-Low-voltage mounting hole; 103-High-voltage mounting hole; 104-Mounting protrusion; 2-PCB board; 3-Relay; 4-Low-voltage plug-in; 5-High-voltage plug-in; 6-Fuse; 7-Temperature sensor; 8-Threaded connector; 9-Top cover; 10-High-voltage wiring harness. Detailed Implementation

[0027] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0028] It should be noted that all directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of the present invention are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indication will also change accordingly.

[0029] The terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, unless otherwise stated, "a plurality of" means two or more.

[0030] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "connected" and "linked" should be interpreted broadly, for example, as a fixed connection, a detachable connection, or an integral connection. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances. Furthermore, when describing pipelines, the terms "connected" and "linked" as used in this application have the meaning of establishing electrical connection. The specific meaning needs to be understood in conjunction with the context.

[0031] In the embodiments of this application, the terms "exemplary" or "for example" are used to indicate that something is an example, illustration, or description. Any embodiment or design that is described as "exemplary" or "for example" in the embodiments of this application should not be construed as being more preferred or advantageous than other embodiments or design. Specifically, the use of the terms "exemplary" or "for example" is intended to present the relevant concepts in a specific manner.

[0032] Both vehicle battery packs and energy storage battery packs involve charging and power distribution systems. Due to different application scenarios and electrical architectures, the design schemes for these systems vary. Vehicle power distribution modules utilize BDU integrated modules, but these modules require customized development, resulting in poor product versatility. Furthermore, the internal component connections and copper busbar wiring with external components all require bolt fixation, leading to high reliance on manual operation and low product consistency and reliability.

[0033] Therefore, please refer to Figure 1 This application provides a vehicle high-voltage power distribution unit, including a base 1, a PCB board 2, a relay 3, a low-voltage plug 4, a high-voltage plug 5, and a fuse 6.

[0034] Please refer to Figure 1 The base 1 has a receiving cavity 101. Low-pressure mounting holes 102 and high-pressure mounting holes 103 are formed on the side wall of the base 1 and communicate with the receiving cavity 101. The low-pressure mounting holes 102 and high-pressure mounting holes 103 are distributed at intervals.

[0035] The structural design of the vehicle's high-voltage power distribution unit needs to take into account insulation safety, mechanical strength, space adaptability, and environmental resistance. Therefore, the base 1 can be made of flame-retardant reinforced nylon or high-temperature resistant PBT material, with glass fiber reinforcement to improve mechanical strength, flame retardant to improve mechanical strength, and flame retardant to provide flame retardant capability.

[0036] Please refer to Figure 1 The base 1 can be in the shape of a cuboid box, forming a closed cavity 101 inside. The bottom of the cavity can be designed with reinforcing ribs to enhance the base 1's resistance to deformation.

[0037] Please refer to Figure 1 The low-pressure mounting hole 102 and the high-pressure mounting hole 103 can be square holes or round holes, depending on the shape and specifications of the plug-in. The low-pressure mounting hole 102 and the high-pressure mounting hole 103 can be stepped holes, with an annular groove provided on the inner side of the hole for installing the sealing ring.

[0038] Please refer to Figure 1 The PCB board 2 is disposed within the receiving cavity 101 of the base 1, and the circuit is printed on the PCB board 2. The substrate 2 can be made of FR4 epoxy resin fiberglass board 2, and the thickness of the copper foil on the surface should meet the current carrying capacity under high voltage and high current transmission. The solder resist layer can be made of high temperature resistant insulating ink to protect the copper foil from oxidation and short circuit.

[0039] The PCB board 2 is usually a rectangular board 2, and its size must be smaller than the cross-section of the cavity 101 of the base 1. The edge can be designed with circular mounting holes that are compatible with the threaded connector 8. The surface is reserved with solder pads for relays 3 and fuses 6 and edge pads for connecting to plug-in components according to the component layout.

[0040] Please refer to Figure 2 Relay 3 is mounted on PCB board 2, and its control circuit is connected to the circuit on PCB board 2. The housing of relay 3 can be made of flame-retardant PBT or PA66, the internal iron core can be made of electrical pure iron or silicon steel sheet, and the contacts can be made of silver-nickel alloy or silver-cadmium alloy.

[0041] Relay 3 is usually in the form of a rectangular block module, and the bottom may have pin-type leads or bolt-type terminals.

[0042] Please refer to Figure 2 The low-voltage plug 4 is located at the low-voltage mounting hole 102. The low-voltage plug 4 is connected to the circuitry on the PCB board 2 and to the control circuitry of the relay 3. The low-voltage plug 4 is used to connect to the power supply and control terminal. The housing of the low-voltage plug 4 can be flame-retardant PA66, the insulating base can be PBT, the terminals can be gold-plated brass, and the sealing ring can be EPDM rubber. Its shape can be a rectangular or round plug structure, and the plug housing can be designed with a snap-fit ​​or threaded locking structure to ensure a secure connection with the mounting hole of the base 1.

[0043] The high-voltage plug-in 5 is housed within the high-voltage mounting hole 103. The high-voltage plug-in 5 is connected to the execution circuit on the relay 3 and is used to connect to a high-voltage power supply and a high-voltage load. The outer shell of the high-voltage plug-in 5 can be reinforced nylon, the insulation layer can be made of high-voltage resistant epoxy resin, the terminals are made of silver-plated copper, and the sealing ring can be made of fluororubber.

[0044] The high-voltage plug 5 can also be a rectangular or circular plug structure. The shape of the high-voltage plug 5 and the low-voltage plug 4 can be the same or different.

[0045] Please refer to Figure 1 Fuse 6 is located between high-voltage plug 5 and relay 3. Fuse 6 can be a fuse with a copper-tin alloy or silver alloy fuse wire.

[0046] Please refer to Figure 1 The vehicle high-voltage power distribution unit provided in this application includes a base 1, a PCB board 2, a relay 3, a low-voltage plug 4, a high-voltage plug 5, and a fuse 6. The PCB board 2, relay 3, and other components are directly installed through the receiving cavity 101 of the base 1, reducing the space occupied by scattered components and improving the overall structural compactness. The spacing between the low-voltage mounting hole 102 and the high-voltage mounting hole 103 can avoid electromagnetic interference between the low-voltage control circuit and the high-voltage power circuit, reduce the risk of short circuit or signal interference, and ensure circuit safety.

[0047] The fuse 6 is connected in series between the high-voltage plug 5 and the relay 3. When a short circuit or overload occurs in the high-voltage circuit, the fuse 6 melts and cuts off the circuit, preventing damage to the relay 3 and the high-voltage load (such as the motor and battery). The connection between the low-voltage plug 4 and the relay 3 control circuit, and the connection between the high-voltage plug 5 and the relay 3 execution circuit, can meet the vehicle's power distribution needs.

[0048] The base 1 in this structure has a convenient shape design and can be adjusted according to needs. The internal relay 3 can also be replaced with different models as needed. The design is convenient and has good versatility. The connection between the components on the PCB board 2 inside the base 1 is simple. There is no need to configure copper busbars. The required circuit connection can be achieved directly through the printed circuit and wiring of the PCB board 2, reducing manual operation and improving product consistency and safety.

[0049] Please refer to Figure 1 It should be noted that the high-voltage power distribution unit for vehicles provided in this solution is suitable for power distribution circuits below 20A, and can be extended to 25A or 30A. For applications with higher currents, the safety and functionality provided by this structure are limited. It can be adapted to applications with higher currents by increasing the number of relays 3 and fuses 6, adding an explosion-proof and flame-retardant structure, and strengthening the base 1 and the wiring.

[0050] Meanwhile, the shape and material of the base 1, PCB board 2, relay 3, low-voltage plug 4, high-voltage plug 5 and fuse 6 are not limited to the examples mentioned above, and may also be other materials or shapes of components used for vehicle power distribution.

[0051] Please refer to Figure 1 In some examples, the vehicle high-voltage power distribution unit also includes a temperature sensor 7, which is mounted on the PCB board 2 and electrically connected to the low-voltage plug-in 4 via the PCB board 2.

[0052] For example, temperature sensor 7 is mounted on PCB board 2 and located between relay 3 and fuse 6.

[0053] Temperature sensor 7 can directly detect the temperature of PCB board 2, relay 3, and fuse 6. The temperature is fed back to the control terminal through the circuit of PCB board 2 and low-voltage plug-in 4, realizing dynamic monitoring of the temperature of key areas inside the power distribution unit. The temperature signal can detect potential faults of relay 3 in advance through temperature changes, thus improving the safety of relay 3.

[0054] For example, the temperature sensor 7 can be placed close to the relay 3 to improve the detection accuracy of the relay 3 and ensure a faster response when the relay 3 experiences a spark or short circuit that causes the temperature to rise.

[0055] In some examples, the temperature sensor 7 can be any of an NTC thermistor sensor, a digital temperature sensor 7, or a thermocouple temperature sensor 7.

[0056] Please refer to Figure 2In some examples, relay 3, fuse 6, and temperature sensor 7 are all soldered onto PCB board 2. Soldering ensures a stable connection between relay 3, fuse 6, and temperature sensor 7 and PCB board 2, while reducing manual operation and improving reliability and consistency compared to bolted connections; additionally, soldering saves space and facilitates spatial design.

[0057] For example, the relay 3 can be a pin-type high-voltage DC relay 3, which can be fixed by through-hole reflow soldering or wave soldering; the fuse 6 can be an axial pin type or a radial pin type structure, and the soldering method can be manual soldering or wave soldering; the temperature sensor 7 is a miniaturized surface mount type or pin type. The pin type temperature sensor 7 can be fixed by wave soldering, and the surface mount type temperature sensor 7 can be directly mounted on the PCB board 2 using surface mount technology.

[0058] Please refer to Figure 1 In some examples, the vehicle high-voltage power distribution unit also includes a threaded connector 8, which securely connects the PCB board 2 and the base 1.

[0059] The threaded connection has high strength and can firmly fix the PCB board 2 in the cavity 101 of the base 1 to resist vehicle vibration; the threaded connector 8 is detachable, which facilitates the assembly, maintenance or replacement of the PCB board 2; the threaded connector 8 is equipped with an insulating bushing, which can further realize the electrical insulation between the PCB board 2 and the base 1.

[0060] For example, a bushing can be installed between the bottom wall of the PCB board 2 and the base 1, and the PCB board 2 can be fixed by the cooperation of the bushing with the threaded connector 8.

[0061] At this time, the number of threaded connectors 8 can be set to correspond to the number of bushings. The number of threaded connectors 8 can be 4, 6 or other numbers; the threaded connectors 8 can be directly made of bolts.

[0062] Please refer to Figure 1 and Figure 3 In some examples, the vehicle high-voltage power distribution unit also includes a cover 9, which covers the opening of the receiving cavity 101 of the base 1.

[0063] The top cover 9 encloses the cavity 101, which can prevent external contaminants such as dust, water vapor, and oil from entering, protecting the internal PCB board 2, relay 3, fuse 6 and other precision components, and avoiding faults such as short circuits and insulation aging caused by contaminants.

[0064] Please refer to Figure 3In some examples, the top cover 9 can be made of the same material as the base 1, such as flame-retardant reinforced nylon or high-temperature resistant PBT, and be set to correspond to the shape of the base 1 for easy installation; warning signs can be printed or etched on the top cover 9 to serve as warnings and identification.

[0065] The upper cover 9 and the base 1 can be connected by snap-fit ​​or by bolts; the connection between the upper cover 9 and the base 1 can also be equipped with a corresponding cooling, flame-retardant, or anti-condensation structure.

[0066] Please refer to Figure 1 In some examples, a mounting protrusion 104 is formed at the end of the base 1 away from the top cover 9. The mounting protrusion 104 is used to fix and connect with the area to be installed. The mounting protrusion 104 can cooperate with the positioning structure of the area to be installed on the vehicle body for quick positioning and to ensure the strength and reliability of the connection. At the same time, the mounting protrusion 104 can be adapted to different vehicle needs and has strong versatility.

[0067] For example, the mounting protrusion 104 is integrally formed with the base 1. The mounting protrusion 104 can be located on the opposite side edges of the base 1 or at multiple corners of the base 1. The number of mounting protrusions 104 can be 2 to 4, preferably 4.

[0068] The mounting protrusion 104 can be cylindrical or square. A through hole can be provided on the mounting protrusion 104, and a bushing can be installed in the through hole so that the base 1 can be fixed to the area to be installed by bolts.

[0069] The installation area can be inside the vehicle body, the energy storage cabinet, or the battery pack.

[0070] Please refer to Figure 4 In some examples, the circuit on PCB board 2 is configured with multiple circuits, which are used to control the control circuit of relay 3 and to collect the temperature signal of temperature sensor 7.

[0071] The relay 3 control circuit and the temperature sensor 7 acquisition circuit are physically isolated to avoid electromagnetic interference between strong and weak electrical signals, ensuring the accuracy of temperature acquisition and the stability of relay 3 control; multiple independent circuits can optimize parameters separately to adapt to the transmission requirements of different signals.

[0072] In some examples, after the low-voltage plug 4 is connected to the low-voltage power supply of the vehicle body (such as 12V), it supplies power to the control circuit of the PCB board 2. When the low-voltage plug 4 receives the high-voltage power-on command from the vehicle controller, the logic circuit of the PCB board 2 outputs a drive signal to the control coil of the relay 3. The coil is energized and generates a magnetic field to make the main contacts close. The high-voltage power supply is input through the high-voltage plug 5 and output to the high-voltage load through the fuse 6, the main contacts of the relay 3 and the high-voltage plug 5 in sequence, realizing the transmission of high-voltage power.

[0073] If the high voltage needs to be disconnected, the low voltage plug-in 4 receives the power-off command, the PCB board 2 cuts off the power supply to the relay 3 coil, and after the coil loses its magnetism, the contacts open under the action of the reset spring, and the high voltage circuit is interrupted.

[0074] The temperature signal acquisition logic is implemented through a closed loop. PCB board 2 provides a stable low-voltage power supply (such as 5V) to temperature sensor 7. The sensor is in close contact with heat-generating components such as relay 3 or fuse 6, converting the physical quantity of temperature into a resistance or voltage signal. After being filtered and amplified by the signal acquisition circuit of PCB board 2, it is transmitted to the vehicle controller in real time through low-voltage plug-in 4.

[0075] When the temperature exceeds the preset threshold, the controller triggers a protection command based on the signal, and the PCB board 2 drives the relay 3 to disconnect the high-voltage circuit, forming an overheat protection closed loop.

[0076] Please refer to Figure 1 In some examples, the low-voltage mounting hole 102 and the high-voltage mounting hole 103 are located on the same side wall of the base 1. This same-side layout reduces the area occupied by the side wall of the base 1, making the power distribution unit more compact and adaptable to the limited installation space of the vehicle.

[0077] In some other examples, the low-pressure mounting hole 102 and the high-pressure mounting hole 103 may also be provided on two different side walls. This structure can be customized according to the requirements of the control wiring harness and actuators inside the vehicle.

[0078] Please refer to Figure 1 In some examples, the high-voltage plug-in 5 is equipped with a high-voltage wiring harness 10, which is used to connect the actuation circuit of the relay 3. The high-voltage wiring harness 10 uses high-voltage and high-current resistant insulating materials and conductive cores to meet the insulation requirements and current carrying requirements of the vehicle's high-voltage circuit.

[0079] In some embodiments, please refer to Figure 1 A vehicle high-voltage power distribution unit includes a base 1, a PCB board 2, a relay 3, a low-voltage plug 4, a high-voltage plug 5, a fuse 6, a temperature sensor 7, a threaded connector 8, and a top cover 9.

[0080] The base 1 is made of flame-retardant insulating material and has a receiving cavity 101, providing installation space and protection for internal components. Low-voltage mounting holes 102 and high-voltage mounting holes 103, communicating with the receiving cavity 101, are formed on the side wall of the base 1. The low-voltage mounting holes 102 and high-voltage mounting holes 103 are spaced apart and located on the same side wall of the base 1. This layout design ensures physical isolation between high and low voltage circuits while facilitating the centralized arrangement and connection of wire harnesses.

[0081] The PCB board 2 is housed within the receiving cavity 101 of the base 1. The PCB board 2 is made of high-strength copper-clad board and has circuits printed on it. The circuits on the PCB board 2 are configured as multiple lines, which are used to control the control circuit of the relay 3 and to collect the temperature signal of the temperature sensor 7, thereby realizing functional zoning and reducing signal interference.

[0082] The PCB board 2 and the base 1 are fixedly connected by a threaded connector 8. The threaded connector 8 is a combination of bolts and insulating bushings. The bolts pass through the mounting holes on the PCB board 2 and the base 1 and are tightened by nuts. The insulating bushing is fitted on the bolts, which realizes electrical insulation and vibration buffering between the PCB board 2 and the base 1.

[0083] Relay 3 is a high-voltage DC relay, mounted on PCB board 2. The control circuit of relay 3 is connected to the circuit on PCB board 2. Relay 3 has a control coil and main contacts. The control coil is connected to low-voltage connector 4 through the circuit on PCB board 2, and the main contacts are connected to high-voltage connector 5 and fuse 6. Relay 3 is fixed to PCB board 2 by soldering, using lead-free solder to ensure connection strength and conductivity.

[0084] The low-voltage connector 4 is a waterproof connector located at the low-voltage mounting hole 102. It is sealed to the base 1 via a sealing ring to prevent moisture from entering the receiving cavity 101. The low-voltage connector 4 is connected to the circuitry on the PCB board 2, specifically through wire soldering to the edge of the PCB board 2. The low-voltage connector 4 is used to connect to the power supply and control terminal, and can receive 12V / 24V low-voltage power from the vehicle battery or low-voltage distribution box, as well as control commands from the vehicle controller (VCU) or ECU, and feed back fault signals from the power distribution unit to the control terminal.

[0085] The high-voltage connector 5 is also a waterproof high-voltage connector, located within the high-voltage mounting hole 103, and sealed to the base 1 via a sealing ring. The high-voltage connector 5 is connected to the execution circuit on the relay 3. The high-voltage connector 5 is equipped with a high-voltage wiring harness 10, which uses high-voltage resistant and wear-resistant cross-linked polyethylene insulation material. One end of the harness is crimped to the terminal of the high-voltage connector 5, and the other end is used to connect to the execution circuit of the relay 3. The high-voltage connector 5 is used to connect to high-voltage power supplies and high-voltage loads, realizing the input and output of high-voltage electrical energy.

[0086] Fuse 6 is a fast-blow fuse, located between the high-voltage plug-in 5 and the relay 3, and fixed to the PCB board 2 by soldering. The input terminal of fuse 6 is connected to the high-voltage input terminal of the high-voltage plug-in 5, and the output terminal is connected to the main contact input terminal of the relay 3. When an overcurrent fault occurs in the high-voltage circuit, fuse 6 can quickly blow, cutting off the high-voltage circuit and protecting downstream components.

[0087] Temperature sensor 7 is an NTC thermistor sensor, located on PCB board 2 near relay 3 and fuse 6, capable of accurately monitoring temperature changes in critical components. Temperature sensor 7 is fixed to PCB board 2 by soldering, and its output signal terminal is connected to the signal acquisition circuit of PCB board 2, which also provides a 5V DC power supply. Temperature sensor 7 is electrically connected to low-voltage connector 4 via PCB board 2, transmitting the acquired temperature signal to the control terminal.

[0088] The top cover 9 is made of the same flame-retardant insulating material as the base 1 and is positioned over the opening of the cavity 101 of the base 1. The top cover 9 is connected to the base 1 by a combination of snaps and screws. The snaps facilitate quick positioning and initial fixation, while the screws are used for tightening, ensuring the reliability and sealing of the connection. The top cover 9 is also equipped with heat dissipation holes to meet the heat dissipation requirements of the internal components and improve heat dissipation efficiency.

[0089] The base 1 has a mounting protrusion 104 at the end away from the top cover 9. The mounting protrusion 104 has mounting holes for fixing to the area to be installed (such as the vehicle frame) with bolts. The number of mounting protrusions 104 is set according to the weight of the power distribution unit and the installation requirements. In this embodiment, four mounting protrusions 104 are provided, evenly distributed at the four bottom corners of the base 1 to ensure the stability of the installation.

[0090] The operation process of the high-voltage power distribution unit in this vehicle is as follows: Please refer to... Figure 5 When the vehicle starts, low-voltage connector 4 connects to the low-voltage power supply, providing power to components such as the PCB board 2 and the control coil of relay 3. The control terminal sends a high-voltage power-on command to the logic circuit of the PCB board 2 through low-voltage connector 4. The logic circuit drives the control coil of relay 3 to be energized, causing the main contacts of relay 3 to close (e.g., ...). Figure 5 (As shown in the purple line). The high-voltage power supply is input through the high-voltage plug-in 5, and outputs to the high-voltage load via the fuse 6, the main contacts of the relay 3, and the high-voltage plug-in 5, thus realizing the transmission of high-voltage electrical energy (e.g., Figure 5 (As shown by the red line in the middle).

[0091] Please refer to Figure 5 During operation, temperature sensor 7 collects temperature signals from key components such as relay 3 and fuse 6 in real time, and transmits them to low-voltage plug-in 4 via the signal acquisition circuit of PCB board 2, and then feeds them back to the control terminal (e.g., Figure 5 (As shown by the green line in the middle). When the temperature exceeds the preset threshold, the control terminal sends a command to PCB board 2, which drives the control coil of relay 3 to de-energize, the main contacts to open, and the high-voltage circuit to be cut off, thus achieving overheat protection.

[0092] When an overcurrent fault occurs in the high-voltage circuit, fuse 6 blows, cutting off the transmission of high-voltage power. At the same time, the circuit on PCB board 2 detects the high-voltage circuit power failure signal and feeds back the fault signal to the control terminal through low-voltage plug-in 4, prompting for fault investigation and repair.

[0093] Please refer to Figure 5 The low-voltage plug-in 4 can also be configured with a circuit connected to the high-voltage plug-in 5 to detect whether the relay 6 is stuck, thereby issuing a timely and accurate warning (such as...). Figure 5 (As shown by the yellow line in the middle).

[0094] In the description of this specification, specific features, structures, materials, or characteristics may be combined in any suitable manner in one or more embodiments or examples.

[0095] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any changes or substitutions within the technical scope disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A vehicle high-voltage power distribution unit, characterized in that, include: The base has a receiving cavity, and low-pressure mounting holes and high-pressure mounting holes communicating with the receiving cavity are formed on the side wall of the base, and the low-pressure mounting holes and the high-pressure mounting holes are distributed at intervals. A PCB board is disposed in the receiving cavity of the base, and the circuit is printed on the PCB board; A relay is mounted on the PCB board, and the control circuit of the relay is connected to the circuit on the PCB board. A low-voltage plug-in is disposed at the low-voltage mounting hole. The low-voltage plug-in is connected to the circuit on the PCB board and to the control circuit of the relay. The low-voltage plug-in is used to connect to the power supply and control terminal. A high-voltage plug is disposed in the high-voltage mounting hole. The high-voltage plug is connected to the execution circuit on the relay. The high-voltage plug is used to connect to a high-voltage power supply and a high-voltage load. A fuse is disposed between the high-voltage plug and the relay.

2. The vehicle high-voltage power distribution unit according to claim 1, characterized in that, The vehicle high-voltage power distribution unit also includes a temperature sensor, which is mounted on the PCB board and electrically connected to the low-voltage plug-in through the PCB board.

3. The vehicle high-voltage power distribution unit according to claim 2, characterized in that, The relay, the fuse, and the temperature sensor are all soldered onto the PCB board.

4. The vehicle high-voltage power distribution unit according to any one of claims 1 to 3, characterized in that, The vehicle high-voltage power distribution unit also includes a threaded connector, and the PCB board and the base are fixedly connected by the threaded connector.

5. The vehicle high-voltage power distribution unit according to any one of claims 1 to 3, characterized in that, The vehicle high-voltage power distribution unit also includes an upper cover, which is disposed over the opening of the base receiving cavity.

6. The vehicle high-voltage power distribution unit according to claim 5, characterized in that, The base has a mounting protrusion at one end away from the top cover, which is used to fix it to the area to be installed.

7. The vehicle high-voltage power distribution unit according to claim 2, characterized in that, The PCB board has multiple circuits, which are used to control the relay's control circuit and to acquire the temperature signal from the temperature sensor.

8. The vehicle high-voltage power distribution unit according to claim 1, characterized in that, The low-pressure mounting hole and the high-pressure mounting hole are located on the same side wall of the base.

9. The vehicle high-voltage power distribution unit according to claim 1, characterized in that, The high-voltage plug is equipped with a high-voltage wiring harness, which is used to connect the relay's execution circuit.

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