Package structure of group charging system host PDU distribution unit

Abstract

The invention discloses a packaging structure of a group charging system host PDU distribution unit. The packaging structure comprises an upper bracket, a lower bracket, a plurality of middle brackets and a plurality of PDU plates, when the packaging structure is arranged in the power distribution cabinet, the upper support faces one end, where an operation port is located, of the power distribution cabinet. The upper bracket comprises an upper bracket panel and an upper bracket frame, and the upper bracket panel is detachably connected with the upper bracket frame; the lower bracket and the upper bracket are oppositely arranged; each middle support is detachably connected with the upper support frame and the lower support, and the plurality of PDU boards are detachably connected to the plurality of middle supports one by one. On one hand, during early-stage wiring, sufficient operation space can be provided for workers by disassembling the upper bracket panel, and the assembly efficiency is ensured; and on the other hand, during later maintenance, the middle bracket corresponding to the PDU board needing to be maintained can be independently detached from the whole packaging structure for replacement or maintenance, so that the convenience of later maintenance is improved.

Description

Technical Field

[0001] This invention relates to the field of PDU packaging technology, and in particular to a packaging structure for a PDU distribution unit of a group charging system host. Background Technology

[0002] A PDU (Power Distribution Unit) is used to distribute power in data centers or industrial equipment. In charging station systems, a PDU needs to manage multiple charging ports or modules and is responsible for distributing power to different charging terminals.

[0003] In existing technologies, the power distribution unit of a charging stack typically employs an integrated PDU package. While this structure, which assembles the PDU board and distribution unit housing as a single unit, offers advantages in structural integrity, it also presents significant limitations in practical applications. Specifically, when PDU board maintenance or wiring operations are required, production personnel must completely disassemble the entire distribution unit, increasing operational complexity and significantly extending maintenance time. Furthermore, the integrated design restricts space for wiring operations during production line assembly, impacting assembly efficiency. These structural drawbacks increase production costs and create numerous inconveniences for later maintenance. Summary of the Invention

[0004] The present invention provides a packaging structure for a PDU distribution unit of a group charging system host, which aims to solve the problem of inconvenient wiring and maintenance caused by the integrated PDU packaging mechanism in the prior art.

[0005] This invention discloses a packaging structure for a PDU distribution unit of a group charging system, including an upper bracket, a lower bracket, several middle brackets, and several PDU boards. When the packaging structure is installed in a power distribution cabinet, the upper bracket faces the end where the operation port of the power distribution cabinet is located. The upper bracket includes an upper bracket panel and an upper bracket frame, and the upper bracket panel and the upper bracket frame are detachably connected. The lower bracket is disposed opposite to the upper bracket. Each middle bracket is detachably connected to the upper bracket frame and the lower bracket, and several PDU boards are detachably connected to several middle brackets.

[0006] In some embodiments, the upper support frame includes a sidewall perpendicular to the upper support panel, and the sidewall is provided with a wiring hole located on one side of the upper support panel.

[0007] In some embodiments, the upper support panel is detachably connected to the upper support frame via a first screw assembly.

[0008] In some embodiments, the side of the upper support frame away from the lower support is recessed toward the side closer to the lower support to form a panel mounting area, the upper support panel is disposed in the panel mounting area, and both ends of the panel are detachably connected to the upper support frame via the first screw assembly.

[0009] In some embodiments, the upper support frame includes a main frame and a connecting frame, the connecting frame being connected to the main frame via a fourth screw assembly, and the connecting frame being located on the side of the main frame closer to the lower support, and one end of the middle support being detachably connected to the connecting frame.

[0010] In some embodiments, the two ends of the middle bracket are detachably connected to the upper bracket frame and the lower bracket respectively via a second screw assembly.

[0011] In some embodiments, the PDU board is connected to the central support via a third screw assembly.

[0012] In some embodiments, the packaging structure of the group charging system host PDU distribution unit further includes a front copper busbar, which is detachably connected to the PDU board via a fifth screw assembly, and each PDU board is connected to multiple front copper busbars.

[0013] In some embodiments, the packaging structure of the group charging system host PDU distribution unit further includes a back copper busbar, which is detachably connected to the PDU board via a sixth screw assembly; the number of back copper busbars is the same as the number of PDU boards.

[0014] In some embodiments, the back copper busbar is connected to both the PDU board and the lower support.

[0015] The beneficial effects of this invention are as follows: The packaging structure of the PDU distribution unit of the group charging system disclosed in this invention includes an upper bracket, a lower bracket, several middle brackets, and several PDU boards. When the packaging structure is installed in a power distribution cabinet, the upper bracket faces the end where the operation port of the power distribution cabinet is located. The upper bracket includes an upper bracket panel and an upper bracket frame, and the upper bracket panel and the upper bracket frame are detachably connected. The lower bracket is arranged opposite to the upper bracket. Each middle bracket is detachably connected to the upper bracket frame and the lower bracket, and several PDU boards are detachably connected to several middle brackets. On the one hand, by setting the upper bracket panel and the upper bracket frame to be detachably connected, during the initial wiring, the upper bracket panel can be disassembled to provide sufficient working space for the staff and ensure assembly efficiency. On the other hand, by setting middle brackets that correspond one-to-one with the PDU boards, and setting each middle bracket to be detachably connected to the upper and lower brackets, during later maintenance, the middle bracket corresponding to the PDU board that needs maintenance can be individually removed from the whole packaging structure for replacement or repair, improving the convenience of later maintenance. Attached Figure Description

[0016] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a front view of the packaging structure of the PDU distribution unit of the group charging system provided in an embodiment of the present invention; Figure 2 for Figure 1 The image shows a front view of the upper bracket in the packaging structure of the PDU distribution unit of the group charging system host. Figure 3 for Figure 2 The front view of the upper bracket panel in the upper bracket shown; Figure 4 for Figure 2 The front view of the upper support frame in the upper support shown; Figure 5 An exploded view of the bracket and PDU board in the packaging structure of the PDU distribution unit of the group charging system host provided in an embodiment of the present invention; Figure 6 A formal diagram showing the packaging structure of the PDU distribution unit of the group charging system provided in this embodiment of the invention when only one middle bracket is installed; Figure 7 This is a rear view of the packaging structure of the PDU distribution unit of the group charging system provided in an embodiment of the present invention; Figure 8This is another front view of the packaging structure of the PDU allocation unit of the group charging system provided in an embodiment of the present invention.

[0018] Reference numerals: 10. Upper bracket; 11. Upper bracket panel; 12. Upper bracket frame; 121. Main frame; 1211. Top wall; 1212. Side wall; 122. Connecting frame; 20. Middle bracket; 21. Bracket main board; 22. Connecting ear; 30. Lower bracket; 40. PDU board; 50. Front copper busbar; 60. Back copper busbar; 70. First screw assembly; 80. Second screw assembly; 90. Third screw assembly; 100. Fourth screw assembly; 110. Fifth screw assembly; 120. Sixth screw assembly. Detailed Implementation

[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] It should be understood that, when used in this specification and the appended claims, the terms "comprising" and "including" indicate the presence of the described features, integrals, steps, operations, elements and, or components, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and, or collections thereof.

[0021] It should also be noted that, unless otherwise explicitly specified and limited, terms such as "installation," "connection," "linking," "fixing," and "setting" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. When an component is referred to as being "on" or "below" another component, the component can be located "directly" or "indirectly" on the other component, or there may be one or more intermediary components. The terms "first," "second," "third," etc., are only for the convenience of describing this technical solution and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, features defined with "first," "second," "third," etc., may explicitly or implicitly include one or more of that feature. For those skilled in the art, the specific meaning of the above terms in this invention can be understood according to the specific circumstances.

[0022] It should also be understood that the terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the invention. As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise.

[0023] It should also be further understood that the terms “and” and “or” as used in this specification and the appended claims refer to any combination of one or more of the associated listed items and all possible combinations, and include such combinations.

[0024] like Figures 1 to 8 As shown, this embodiment of the invention discloses a packaging structure for a PDU allocation unit of a group charging system host. Figure 1 This is a front view of the packaging structure of the PDU distribution unit of the group charging system provided in an embodiment of the present invention; Figure 2 for Figure 1 The image shows a front view of the upper bracket in the packaging structure of the PDU distribution unit of the group charging system host. Figure 3 for Figure 2 The front view of the upper bracket panel in the upper bracket shown; Figure 4 for Figure 2 The front view of the upper support frame in the upper support shown; Figure 5 An exploded view of the bracket and PDU board in the packaging structure of the PDU distribution unit of the group charging system host provided in an embodiment of the present invention; Figure 6 A formal diagram showing the packaging structure of the PDU distribution unit of the group charging system provided in this embodiment of the invention when only one middle bracket is installed; Figure 7 This is a rear view of the packaging structure of the PDU distribution unit of the group charging system provided in an embodiment of the present invention; Figure 8 This is another front view of the packaging structure of the PDU allocation unit of the group charging system provided in an embodiment of the present invention.

[0025] Specifically, the group charging system can be a group charging system for charging piles. The PDU distribution unit is used to distribute the power from the grid or power source to different loads, i.e., charging piles. The packaged structure is installed in the power distribution cabinet after assembly.

[0026] See together 1 to Figure 8The packaging structure of the main unit PDU distribution unit of the group charging system may include an upper bracket 10, a lower bracket 30, a plurality of middle brackets 20, and a plurality of PDU boards 40. When the packaging structure is installed in the power distribution cabinet, the upper bracket 10 faces the end where the operation port of the power distribution cabinet is located. The upper bracket 10 includes an upper bracket panel 11 and an upper bracket frame 12, and the upper bracket panel 11 and the upper bracket frame 12 are detachably connected. The lower bracket 30 is disposed opposite to the upper bracket 10. Each middle bracket 20 is detachably connected to the upper bracket frame 12 and the lower bracket 30, and the plurality of PDU boards 40 are detachably connected one by one to the plurality of middle brackets 20.

[0027] In this embodiment, the upper bracket 10 and the lower bracket 30 serve as the skeleton or housing of the PDU distribution unit to support the middle bracket 20 and the PDU board 40, which is the circuit board of the PDU distribution unit. The middle bracket 20 serves as an intermediate support member for stably mounting the PDU board 40 on the upper bracket 10 and the lower bracket 30.

[0028] When the encapsulation structure is installed inside the distribution cabinet, the upper bracket 10 faces the end of the distribution cabinet with its operating port. Workers can perform wiring operations through this port. The upper bracket panel 11 and the upper bracket frame 12 are designed to be detachably connected. When wiring operations are required, the upper bracket panel 11 can be removed from the upper bracket frame 12, freeing up work space and improving the convenience of wiring operations. After wiring is completed, the upper bracket panel 11 is reinstalled onto the upper bracket frame 12. Other electrical components of the PDU distribution unit are mounted on the upper bracket panel 11.

[0029] During later maintenance, if a single PDU board 40 malfunctions or experiences an abnormality, on-site after-sales maintenance personnel only need to remove the encapsulation structure from the power distribution cabinet. They only need to remove the corresponding middle bracket 20 from the upper bracket frame 12 and the lower bracket 30. Since the PDU board 40 is directly mounted on the middle bracket 20, it is also removed from the entire encapsulation structure, allowing for repair or replacement of the PDU board 40. During specific repair or replacement, the PDU board 40 can also be removed from the middle bracket 20. For example, when replacing PDU board 40, the operator can choose to replace the middle bracket 20 and PDU board 40 together. That is, the spare middle bracket 20 and PDU board 40 can be pre-assembled. After disassembling the faulty PDU board 40 and middle bracket 20 from the overall packaging structure, the pre-assembled middle bracket 20 and PDU board 40 are installed on the upper bracket 10 and lower bracket 30 to improve maintenance efficiency. Alternatively, the operator can choose to remove PDU board 40 from the middle bracket 20, install the new PDU board 40 on the middle bracket 20, and then install the assembled middle bracket 20 and PDU board 40 on the upper bracket 10 and lower bracket 30, that is, only PDU board 40 is replaced, reducing material costs.

[0030] In summary, in this embodiment, on the one hand, the upper bracket panel 11 and the upper bracket frame 12 are detachably connected. During the initial wiring, the upper bracket panel 11 can be disassembled to provide sufficient working space for the staff and ensure assembly efficiency. On the other hand, by setting up middle brackets 20 that correspond one-to-one with the PDU board 40, and setting each middle bracket 20 to be detachably connected with the upper bracket 10 and the lower bracket 30, during later maintenance, the middle bracket 20 corresponding to the PDU board 40 that needs maintenance can be individually removed from the overall packaging structure for replacement or repair, improving the convenience of later maintenance.

[0031] Therefore, compared to the existing technology where the PDU board 40 is assembled as a whole with the housing, resulting in limited space for wiring operations and affecting assembly efficiency, and when PDU maintenance or wiring operations are required, production personnel must completely disassemble the entire distribution unit, which is complicated and time-consuming, the split design of this embodiment not only ensures the working space for wiring in the early stage, but also improves the convenience of later maintenance.

[0032] In a specific embodiment, the upper support frame 12 includes a side wall 1112 perpendicular to the upper support panel 11, and the side wall 1112 is provided with a wiring hole (not shown in the figure), which is located on one side of the upper support panel 11.

[0033] The upper support frame 12 includes a top wall 1211 and a side wall 1112. The top wall 1211 and the upper support panel 11 are basically on the same plane. The side wall 1112 is perpendicular to the side edge of the top wall 1211, meaning it is also perpendicular to the upper support panel 11. The wiring hole is located on the back side of the upper support panel 11, and is used to arrange wires so that they can pass through the side wall 1112. During the initial wiring process, the upper support panel 11 is removed from the upper support frame 12, which makes it easier for workers to perform wiring operations.

[0034] In a specific embodiment, the upper support panel 11 is detachably connected to the upper support frame 12 via a first screw assembly 70.

[0035] The first screw assembly 70 can be multiple M6×16 screws. The overlapping part of the upper bracket panel 11 and the upper bracket frame 12 is provided with mating holes to mate with the first screw assembly 70, so as to realize the detachable connection between the upper bracket panel 11 and the upper bracket frame 12.

[0036] In a specific embodiment, the side of the upper support frame 12 away from the lower support 30 is recessed towards the side closer to the lower support 30 to form a panel mounting area. The upper support panel 11 is disposed in the panel mounting area, and both ends of the panel are detachably connected to the upper support frame 12 through the first screw assembly 70.

[0037] The first screw assembly 70 can consist of four M6×16 screws. The top wall 1211 of the upper bracket frame 12 is recessed from the side away from the lower bracket 30 to the side closer to the lower bracket 30 to form a panel mounting area. The aforementioned side wall 1112 is vertically connected to the edge of the top wall 1211 near the lower bracket 30. The shape and size of this panel mounting area are adapted to the shape and size of the upper bracket panel 11. Specifically, when the upper bracket panel 11 is mounted on the upper bracket frame 12, the opposite ends of the upper bracket panel 11 overlap with the side wall 1112 and are respectively connected to the top wall 1211 of the upper bracket frame 12 by two M6×16 screws. The side of the upper bracket panel 11 away from the lower bracket 30 is on the same straight line as the side of the upper bracket frame 12 away from the lower bracket 30.

[0038] In a specific embodiment, the upper support frame 12 includes a main frame 121 and a connecting frame 122. The connecting frame 122 is connected to the main frame 121 through a fourth screw assembly 100, and the connecting frame 122 is located on the side of the main frame 121 near the lower support 30. One end of the middle support 20 is detachably connected to the connecting frame 122.

[0039] Among them, the top wall 1211 and the side wall 1112 belong to the main frame 121. The top wall 1211 is provided with a plurality of connecting ends. The plurality of connecting ends are spaced apart along the length direction of the side of the top wall 1211 near the lower support 30. The plurality of connecting ends overlap with the connecting frame 122. The overlapping part is provided with mating holes to cooperate with the fourth screw assembly 100 to connect the main frame 121 and the connecting frame 122.

[0040] In a specific embodiment, the two ends of the middle bracket 20 are detachably connected to the upper bracket frame 12 and the lower bracket 30 respectively via the second screw assembly 80.

[0041] Several intermediate supports 20 are longitudinally arranged between the upper support frame 12 and the lower support 30. Each intermediate support 20 is connected to both ends of the upper support frame 12 and the lower support 30 via a second screw assembly 80. This means each intermediate support 20 can be individually detached from the overall packaging structure. Specifically, the second screw assembly 80 is an M4 screw, and each end of the intermediate support 20 is connected to the upper support frame 12 and the lower support 30 via an M4 screw. The end of the intermediate support 20 connected to the upper support frame 12 is specifically connected to a connecting frame 122. The connecting frame 122 has not only a mating hole for the fourth screw assembly 100 but also a mating hole for the second screw assembly 80. These two types of mating holes can be staggered to ensure a sufficient number of connection points between the connecting frame 122 and the upper support frame 12 and the intermediate support 20, resulting in a compact connection between the three components.

[0042] In a specific embodiment, the PDU board 40 is connected to the central support 20 via a third screw assembly 90.

[0043] The third screw assembly 90 is an M3 screw. Each intermediate bracket 20 includes a longitudinally elongated bracket main board 21 and connecting ears 22 at both ends of the bracket main board 21, with the connecting ears 22 perpendicular to the bracket main board 21. When the PDU board 40 is mounted on the intermediate bracket 20, the PDU board 40 is parallel to the bracket main board 21. When the PDU board 40 is connected to the upper bracket 10 and the lower bracket 30, the bracket main board 21 is placed laterally between the upper bracket 10 and the lower bracket 30. One end of its connecting ear 22 is connected to the connecting frame 122 by an M3 screw, and the other end of its connecting ear 22 is connected to the lower bracket 30 by an M3 screw. The lateral placement of the bracket main board 21 means that the PDU board 40 is also laterally positioned between the upper bracket 10 and the lower bracket 30, so that the top of the row of terminals on each PDU board 40 faces the front of the overall packaging structure, and the bottom faces the back of the overall packaging structure.

[0044] In a specific embodiment, the packaging structure also includes a front copper busbar 50, which is detachably connected to the PDU board 40 via a fifth screw assembly 110, and each PDU board 40 is connected to multiple front copper busbars 50.

[0045] The front copper busbar 50 serves as a sub-copper busbar of the distribution unit, used to connect the distribution unit and the load terminals via wires, so as to transmit electrical energy from the power supply or grid to multiple load terminals. The fifth screw assembly 110 can be an M6×16 screw, and each front copper busbar 50 is connected to the front of a row of terminals via multiple M6×16 screws.

[0046] In a specific embodiment, the packaging structure further includes a back copper busbar 60, which is detachably connected to the PDU board 40 via a sixth screw assembly 120; the number of back copper busbars 60 is the same as the number of PDU boards 40.

[0047] The back copper busbar 60 serves as the mother copper busbar of the distribution unit. It is used to connect the power supply terminal or grid terminal to the distribution unit through a conductor, so as to transmit electrical energy to the distribution unit. Then, the power is distributed to each load terminal through the sub-copper busbar, i.e., the front copper busbar 50, and the conductor. The sixth screw assembly 120 can be an M6×14 screw. Each back copper busbar 60 is connected to the back of a row of terminals on a PDU board 40 by multiple M6×14 screws.

[0048] In a specific embodiment, the back copper busbar 60 is connected to both the PDU board 40 and the lower bracket 30.

[0049] Each of the back copper busbars 60 is longitudinally elongated. When it is connected to the back of the terminal block by multiple M6×14 screws, it is also connected to the lower bracket 30 by M6×14 screws and insulating posts to ensure the stability of the connection.

[0050] Finally, based on the above embodiments, the packaging structure of the PDU distribution unit of the group charging system host is explained in terms of the wiring method during the initial stage and the maintenance method during the later stage: During the production and assembly phase, the packaging structure is first assembled into a complete module according to the connection relationship described above. Subsequently, it is precisely installed into the power distribution cabinet using an automated robotic arm. When entering the electrical wiring stage, the upper bracket panel 11 can be removed to make room for wiring and improve the convenience of wiring operations. After the wiring is completed, the upper bracket panel 11 can be reinstalled into the upper bracket frame 12. During this process, ample working space is provided for production personnel.

[0051] In terms of post-maintenance, if a single PDU circuit board malfunctions or experiences an abnormality, on-site after-sales maintenance personnel only need to perform the following standardized operating procedures: First, remove the entire package structure from the cabinet. Then, remove the M6×14 screws on the back copper busbar 60 and the front copper busbar 50 of the middle bracket 20 corresponding to the faulty PDU board 40. Finally, remove the M4 screws at both ends of the middle bracket 20 to remove the middle bracket 20 together with the PDU board 40 from the package structure. This allows for the disassembly and replacement of the individual PDU board 40. This modular design ensures assembly efficiency and greatly improves the convenience of post-maintenance, effectively reducing the time and labor costs of equipment maintenance.

[0052] The above are merely specific embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in the present invention, and these modifications or substitutions should all be covered within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A packaging structure for a PDU distribution unit of a group charging system host, characterized in that, It includes an upper bracket, a lower bracket, several middle brackets, and several PDU boards; when the encapsulation structure is installed inside the power distribution cabinet, the upper bracket faces the end where the operation port of the power distribution cabinet is located; the upper bracket includes an upper bracket panel and an upper bracket frame, and the upper bracket panel and the upper bracket frame are detachably connected; the lower bracket is arranged opposite to the upper bracket; each of the middle brackets is detachably connected to the upper bracket frame and the lower bracket, and the several PDU boards are detachably connected one by one to the several middle brackets.

2. The packaging structure of the PDU distribution unit of the group charging system host according to claim 1, characterized in that, The upper support frame includes a side wall perpendicular to the upper support panel, and the side wall is provided with a wiring hole located on one side of the upper support panel.

3. The packaging structure of the PDU distribution unit of the group charging system host according to claim 1, characterized in that, The upper support panel is detachably connected to the upper support frame via a first screw assembly.

4. The packaging structure of the PDU distribution unit of the group charging system host according to claim 3, characterized in that, The upper support frame is recessed from the side away from the lower support to the side closer to the lower support to form a panel mounting area. The upper support panel is disposed in the panel mounting area, and both ends of the panel are detachably connected to the upper support frame through the first screw assembly.

5. The packaging structure of the PDU distribution unit of the group charging system host according to claim 4, characterized in that, The upper support frame includes a main frame and a connecting frame. The connecting frame is connected to the main frame via a fourth screw assembly, and the connecting frame is located on the side of the main frame closer to the lower support. One end of the middle support is detachably connected to the connecting frame.

6. The packaging structure of the PDU distribution unit of the group charging system host according to claim 1, characterized in that, The two ends of the middle bracket are detachably connected to the upper bracket frame and the lower bracket respectively via a second screw assembly.

7. The packaging structure of the PDU distribution unit of the group charging system host according to claim 1, characterized in that, The PDU board is connected to the central support via a third screw assembly.

8. The packaging structure of the PDU distribution unit of the group charging system host according to claim 1, characterized in that, It also includes a front copper busbar, which is detachably connected to the PDU board via a fifth screw assembly, and each PDU board is connected to multiple front copper busbars.

9. The packaging structure of the PDU distribution unit of the group charging system host according to claim 1, characterized in that, It also includes a back copper busbar, which is detachably connected to the PDU board via a sixth screw assembly; the number of the back copper busbars is the same as the number of the PDU boards.

10. The packaging structure of the PDU distribution unit of the group charging system host according to claim 9, characterized in that, The back copper busbar is connected to both the PDU board and the lower bracket.

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