Manufacturing method of a battery pack power distribution unit and power distribution unit

Abstract

The application relates to a manufacturing method of a battery pack power distribution unit and the power distribution unit, and relates to the technical field of the battery pack power distribution unit, which comprises the following steps: collecting a vehicle type and a reference specification; calling an installation position of the power distribution unit from the vehicle type; obtaining a driving model through the installation position, the reference specification and the vehicle type; forming a heat dissipation parameter based on the driving model; calling an installation component from the reference specification; obtaining a shell manufacturing parameter according to the vehicle type, the driving model and the installation component; obtaining a shell internal air direction by combining the heat dissipation parameter and the shell manufacturing parameter; calling a heating position and a copper bar installation position from the driving model; obtaining a transmission direction according to the heating position and the copper bar installation position; obtaining a flow direction by combining the transmission direction and the shell internal air direction; obtaining a manufacturing parameter through the flow direction and the reference specification, adding the shell manufacturing parameter to the manufacturing parameter, and uploading and outputting the manufacturing parameter. The application has the effect of improving the adaptability of the power distribution unit.

Description

Technical Field

[0001] This invention relates to the technical field of battery pack power distribution units, and in particular to a method for manufacturing a battery pack power distribution unit and the power distribution unit itself. Background Technology

[0002] The battery pack power distribution unit is a core power control component adapted to new energy high-voltage electrical systems, and is mainly integrated inside the battery pack of new energy vehicles.

[0003] In the process of manufacturing power distribution units, the manufacturing of power distribution units relies on manual experience or single parameter matching. Manual labor usually uses the standard specifications of the power distribution unit itself to manufacture step by step, and then installs the manufactured power distribution units of the same specifications into different cars for use.

[0004] During the production of power distribution units, the installation location of the power distribution units varies depending on the type of vehicle. This can cause the heat dissipation parts of the power distribution units to be blocked and unusable in different vehicles, resulting in low compatibility of the manufactured power distribution units. Summary of the Invention

[0005] To improve the adaptability of the power distribution unit, the present invention provides a method for manufacturing a battery pack power distribution unit and the power distribution unit itself.

[0006] In a first aspect, the present invention provides a method for manufacturing a battery pack power distribution unit, employing the following technical solution:

[0007] A method for manufacturing a battery pack power distribution unit includes:

[0008] S10: Collect the baseline specifications of the vehicle type and power distribution unit;

[0009] S11: Retrieve the installation location of the power distribution unit from the vehicle type;

[0010] S12: Obtain a driving model by determining the installation location, baseline specifications, and vehicle type;

[0011] S13: Based on the driving model to generate heat dissipation parameters;

[0012] S14: Retrieve the installation components of the power distribution unit from the reference specifications;

[0013] S15: Obtain the shell manufacturing parameters based on the vehicle type, driving model, and mounting components;

[0014] S16: The airflow direction inside the casing is obtained by combining heat dissipation parameters and casing manufacturing parameters;

[0015] S17: Retrieve the heating location and copper busbar installation location of the copper busbar assembly from the driving model;

[0016] S18: The transmission direction is determined based on the heating location and the copper busbar installation location;

[0017] S19: Combine the transmission direction with the wind direction inside the shell to obtain the guiding direction;

[0018] S110: Obtain manufacturing parameters through the flow direction and reference specifications, add the housing manufacturing parameters to the manufacturing parameters, and upload and output the manufacturing parameters.

[0019] By adopting the above technical solution, manufacturing parameters are obtained by analyzing the vehicle type and benchmark specifications, and then the manufacturing parameters are uploaded and output to achieve precise matching between the manufacturing parameters of the power distribution unit and the vehicle type and installation location. This reduces the problem of blockage in the heat dissipation parts of the power distribution unit. Furthermore, the manufacturing of the copper busbar assembly is designed based on the manufacturing conditions of the heat dissipation parts to guide the airflow inside the housing. This further improves the heat dissipation function of the power distribution unit while enhancing its adaptability.

[0020] Optionally, methods for obtaining the casing manufacturing parameters include:

[0021] S20: Retrieve installation specifications from vehicle type;

[0022] S21: Retrieve the battery pack location from the driving model;

[0023] S22: The installation type of the power distribution unit is obtained by the installation specifications and the location of the battery pack;

[0024] S23: When the installation type is the preset bonding type, the bonding surface is obtained based on the driving model, installation specifications and battery pack position;

[0025] S24: Obtain the housing manufacturing parameters based on the bonding surface.

[0026] Optionally, methods for obtaining manufacturing parameters may also include:

[0027] S30: Combine the flow direction with the reference specifications to obtain the design type of the copper busbar assembly;

[0028] S31: Obtain the variable parts by designing the type and standard specifications;

[0029] S32: Update the driving model based on the changed parts;

[0030] S33: Retrieve the operating power value and reference current carrying capacity from the vehicle type, and simulate the driving model using the operating power value;

[0031] S34: Retrieve the actual current carrying capacity from the driving model;

[0032] S35: Compare the actual carrying current with the reference carrying current to update the design type in case of exceedance;

[0033] S36: Manufacturing parameters are obtained based on the design type and baseline specifications.

[0034] By adopting the above technical solution, manufacturing parameters are obtained by analyzing the design types of copper busbar components. This allows for the formation of corresponding manufacturing parameters based on the changes in heat dissipation performance in different design types, and enables the design type with maximized heat dissipation to be obtained while acquiring the manufacturing parameters.

[0035] Optional design-type validation methods include:

[0036] S40: The heat dissipation rate inside the shell is obtained based on heat dissipation parameters and airflow direction inside the shell.

[0037] S41: Based on the design type, operating power value, and driving model, the marked output heat is obtained;

[0038] S42: The baseline output heat is obtained by using the baseline specifications, operating power values, and driving model;

[0039] S43: Obtain the rate of heat change by comparing the marked output heat with the reference output heat;

[0040] S44: Compare the internal heat dissipation rate with the rate of thermal change to update the design type.

[0041] Optional methods for updating design types include:

[0042] S50: Determine whether the actual carrying current exceeds the reference carrying current;

[0043] S51: When the actual carrying current exceeds the reference carrying current, continue to output the design type;

[0044] S52: When the actual carrying current does not exceed the reference carrying current, the difference between the actual carrying current and the reference carrying current is calculated as the deviation carrying current;

[0045] S53: Based on the deviation carrying current and design type, the change dimensions of the variable parts are obtained;

[0046] S54: Update the design type based on the changing dimensions.

[0047] Optional methods for updating design types include:

[0048] S60: Retrieve the baseline process from the baseline specification;

[0049] S61: Update the baseline process by changing the dimensions, and obtain the anomaly type based on the baseline process;

[0050] S62: To create a manufacturing model based on the baseline process, design type, and baseline specifications;

[0051] S63: Retrieve process quantities from the production model;

[0052] S64: Obtain the anomaly weight score based on the manufacturing model, number of processes, and anomaly type;

[0053] S65: The rate deviation value is calculated as the difference between the heat dissipation rate inside the shell and the rate of heat change, depending on the design type.

[0054] S66: Obtain a comprehensive weight score by combining the abnormal weight score with the rate deviation value, and update the design type with the highest comprehensive weight score.

[0055] Optional methods for verifying abnormal weight scores include:

[0056] S70: Retrieve the abnormal process part of the abnormal type from the manufacturing model;

[0057] S71: Obtain the split-and-combination process by comparing abnormal process parts with the baseline process, and update the manufacturing model with the split-and-combination process.

[0058] S72: Retrieve abnormal dimensional parameters of abnormal process parts from the design type;

[0059] S73: Obtain the combination anomaly type based on the splitting and combining process;

[0060] S74: Combine the combined anomaly type with the model and anomaly size parameters to obtain the combined weight score;

[0061] S75: Update abnormal weight scores based on combined weight scores.

[0062] Secondly, this application provides a battery pack power distribution unit, which utilizes the aforementioned manufacturing method for a battery pack power distribution unit and adopts the following technical solution:

[0063] A battery pack power distribution unit includes an LDS lower housing assembly, a bottom protective cover connected to the LDS lower housing assembly to form a cavity, a relay located in the cavity and connected to the LDS lower housing assembly, a PCBA board connected to the LDS lower housing assembly and used to control the opening and closing of the relay, and a copper busbar assembly connected to the relay and used to assist the PCBA board in controlling the opening and closing of the relay.

[0064] The lower housing assembly of the LDS is provided with control lines for connecting the relay and the PCBA board;

[0065] A metal spring is provided between the copper busbar assembly and the LDS lower housing assembly.

[0066] Optionally, three copper busbar assemblies are provided. The copper busbar assembly on the relay is connected to the positive and negative terminals of the battery pack respectively. Another copper busbar assembly is located between the PCBA board and the LDS lower housing assembly. The relay is provided with a baffle to prevent the high-voltage arc generated by the copper busbar assembly from directly breaking down the air and forming a short circuit.

[0067] In summary, this application includes at least one of the following beneficial technical effects:

[0068] 1. By analyzing the vehicle type and benchmark specifications to obtain manufacturing parameters, and uploading and outputting the manufacturing parameters, the manufacturing parameters of the power distribution unit are accurately matched with the vehicle type and installation location, reducing the problem of blockage in the heat dissipation parts of the power distribution unit. Based on the manufacturing conditions of the heat dissipation parts, the manufacturing conditions of the installation parts are designed to guide the airflow inside the housing, thereby further improving the heat dissipation function of the power distribution unit and improving the adaptability of the power distribution unit.

[0069] 2. By analyzing the heat dissipation parameters of the vehicle type and the housing manufacturing parameters to obtain the airflow direction, the manufacturing parameters can be determined. This allows for the modification of the manufacturing parameters of the power distribution unit to improve its heat dissipation performance during use without affecting its operation.

[0070] 3. By analyzing the design types of copper busbar components to obtain manufacturing parameters, corresponding manufacturing parameters can be formed according to the changes in heat dissipation performance in different design types, and the design type that maximizes heat dissipation can be obtained at the same time as obtaining the manufacturing parameters. Attached Figure Description

[0071] Figure 1 This is an overall schematic diagram of a battery pack power distribution unit according to an embodiment of the present invention;

[0072] Figure 2 This is an exploded view of a battery pack power distribution unit according to an embodiment of the present invention;

[0073] Figure 3 This is a schematic diagram of the control circuit in the LDS lower housing assembly according to an embodiment of the present invention.

[0074] The parts referred to by the numbers in the above attached figures are as follows: 1. LDS lower housing assembly; 2. Bottom protective cover; 3. Cavity; 4. Relay; 5. PCBA board; 6. Copper busbar assembly; 7. Control circuit; 8. Metal spring; 9. Partition. Detailed Implementation

[0075] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.

[0076] Reference Figure 1 and Figure 2 A battery pack power distribution unit includes an LDS lower housing assembly 1, a bottom protective cover 2 connected to the LDS lower housing assembly 1 to form a cavity 3, a relay 4 located in the cavity 3 and connected to the LDS lower housing assembly 1, a PCBA board 5 connected to the LDS lower housing assembly 1 and used to control the opening and closing of the relay 4, and a copper busbar assembly 6 connected to the relay 4 and used to assist the PCBA board 5 in controlling the opening and closing of the relay 4.

[0077] Reference Figure 2 and Figure 3 The LDS lower housing assembly 1 is provided with a control line 7 for connecting the relay 4 and the PCBA board 5. In this embodiment, the control line 7 is formed by laser engraving when the LDS lower housing assembly 1 is injection molded with LDS material. The activated lower housing is then electroplated. After being activated by laser engraving, the high and low voltage control lines 7 will form a metal conductive layer after electroplating, thereby reducing the number of components such as wire harnesses, and thus reducing the weight and cost of the product.

[0078] Reference Figure 2 There are three copper busbar assemblies 6. Two of them are mounted on the relay 4 for connection to the positive and negative terminals of the battery pack, respectively. The relay 4 has an integral partition 9 to prevent the high-voltage arc generated when the copper busbar assembly 6 is connected to the battery pack from directly breaking down the air and causing a short circuit. The third copper busbar assembly 6 is located between the PCBA board 5 and the control line 7.

[0079] Reference Figure 2 Metal springs 8 are provided between the copper busbar assembly 6 and the LDS lower housing assembly 1 to enable simultaneous conduction between the copper busbar assembly 6 and the PCBA board 5 and the control circuit 7. The copper busbar assembly 6 forms a signal bridge between the PCBA board 5 and the relay 4. The PCBA board 5 is used to realize communication with the vehicle BMS. The control commands of the vehicle BMS are transmitted to the relay 4 through the copper busbar assembly 6 on the PCBA board 5 and the control circuit 7 to control its opening and closing. In this embodiment, the PCBA board 5 includes a shunt.

[0080] Based on the same inventive concept, this application discloses a method for manufacturing a battery pack power distribution unit, including the following steps:

[0081] S10: Collect the baseline specifications of the vehicle type and power distribution unit.

[0082] Vehicle type refers to the specification type of the vehicle that needs to install the power distribution unit. Base specifications refer to the names, dimensions, and material specifications of each component of the power distribution unit, which can be obtained through pre-input by the operator.

[0083] S11: Retrieve the installation location of the power distribution unit from the vehicle type.

[0084] The installation location refers to the location in the vehicle where the electrical distribution unit is installed. The installation location is determined by retrieving the electrical distribution unit's installation location from the vehicle type.

[0085] S12: Obtain the driving model by determining the installation location, reference specifications, and vehicle type.

[0086] A driving model is a three-dimensional virtual data model of a vehicle with a standard-specification electrical distribution unit installed at the installation location. Data parameters corresponding to the installation location, standard specifications, and vehicle type are input into 3D modeling software (such as CATIA, SolidWorks, etc.) to form a driving model for subsequent fluid dynamics and thermal simulation analysis. The method for forming the driving model is common knowledge to those skilled in the art and will not be elaborated upon here.

[0087] S13: Based on the driving model to generate heat dissipation parameters.

[0088] Heat dissipation parameters refer to the set of physical quantities used to quantify the heat dissipation effect of a vehicle equipped with a power distribution unit. These include, but are not limited to, steady-state temperature field distribution, hot spot temperature, flow velocity distribution, convective heat transfer coefficient, and system thermal resistance. These parameters are obtained through numerical simulation of the driving model using computational fluid dynamics (CFD) simulation software (such as ANSYS Fluent or Star-CCM+). The simulation process involves setting appropriate boundary conditions, such as ambient temperature, battery pack heating power, and initial flow velocity. The setting of boundary conditions and the simulation methods for the driving model are common knowledge to those skilled in the art and will not be elaborated upon here.

[0089] S14: Retrieve the installation components of the power distribution unit from the reference specifications.

[0090] Mounting components refer to the specific components that make up the power distribution unit. The mounting components of the power distribution unit are retrieved from the reference specifications. The mounting components include LDS lower housing assembly 1, bottom protective cover 2, relay 4, PCBA board 5, copper busbar assembly 6, and metal spring 8.

[0091] S15: Obtain the shell manufacturing parameters based on the vehicle type, driving model, and mounting components.

[0092] The housing manufacturing parameters refer to the core data for the production of the LDS lower housing assembly 1 of the power distribution unit. These parameters mainly include the three-dimensional model of the LDS lower housing assembly 1. The housing manufacturing parameters are obtained by analyzing the vehicle type, driving model, and installation components.

[0093] S16: The airflow direction inside the casing is obtained by combining the heat dissipation parameters and the casing manufacturing parameters.

[0094] The airflow direction inside the enclosure refers to the main direction and velocity distribution of airflow within cavity 3 of the power distribution unit. By importing the enclosure manufacturing parameters into CFD software and loading the heat dissipation parameters obtained in step S13 as boundary conditions, internal flow field simulation is performed to retrieve the visualized airflow direction within cavity 3 of the power distribution unit as the airflow direction inside the enclosure.

[0095] S17: Retrieve the heating location and copper busbar installation location of the copper busbar assembly from the driving model.

[0096] The heat-generating location refers to the location where the power distribution unit of the standard specification is prone to heat generation during operation. The copper busbar installation location refers to the location where the copper busbar assembly 6 of the power distribution unit is installed in the vehicle. The heat-generating location and the copper busbar installation location of the copper busbar assembly 6 are retrieved from the driving model.

[0097] S18: The transmission direction is determined based on the heating location and the copper busbar installation location.

[0098] The transmission direction refers to the shortest spatial vector between the heating location and the copper busbar installation location. This shortest spatial vector is calculated using three-dimensional vectors and is taken as the transmission direction. The method for calculating the three-dimensional vector is common knowledge to those skilled in the art and will not be elaborated upon here.

[0099] S19: Combine the transmission direction with the wind direction inside the shell to obtain the flow direction.

[0100] The airflow direction refers to the orientation in which airflow is guided to optimize heat dissipation. By comparing the vector of the transmission direction with the vector of the airflow direction inside the enclosure, and analyzing the vector relationship between the transmission direction and the airflow direction inside the enclosure, the airflow requirements for optimizing the heat dissipation structure can be determined. Thus, the airflow direction inside the enclosure is guided into the transmission direction through the airflow direction. The method of analyzing the airflow direction using vectors is common knowledge to those skilled in the art and will not be elaborated here.

[0101] S110: Obtain manufacturing parameters through the flow direction and reference specifications, add the housing manufacturing parameters to the manufacturing parameters, and upload and output the manufacturing parameters.

[0102] The specifications of copper busbar assembly 6 are analyzed by varying the flow direction and baseline specifications to obtain its manufacturing parameters (the remaining components remain at the baseline specifications). The housing manufacturing parameters are then added to the overall manufacturing parameters, and these parameters are uploaded and output to the operator's terminal. In this embodiment, multiple manufacturing parameters exist, and the final manufacturing parameters for the power distribution unit are determined based on the operator's selection.

[0103] Methods for obtaining the casing manufacturing parameters include:

[0104] S20: Retrieve installation specifications from vehicle type.

[0105] Installation specifications refer to the structural specifications reserved in the vehicle design for the installation of the power distribution unit, including mounting hole positions, bolt specifications, allowable envelope space dimensions, and sealing surface requirements, etc., which are obtained by retrieving the installation specifications from the vehicle type.

[0106] S21: Retrieve the battery pack location from the driving model.

[0107] The battery pack location refers to the location in the car design where the battery pack is installed, which is obtained by retrieving the battery pack location from the driving model.

[0108] S22: The installation type of the power distribution unit is obtained by the installation specifications and the location of the battery pack.

[0109] Installation type refers to the classification of the relative position and connection relationship between the power distribution unit and the battery pack, such as "top-mounted", "side-mounted", and "embedded". By using computer-aided design (CAD) software to perform spatial matching analysis between the constraints in the installation specifications and the battery pack position, the corresponding type from "top-mounted", "side-mounted", and "embedded" is selected as the installation type.

[0110] S23: When the installation type is the preset bonding type, the bonding surface is obtained based on the driving model, installation specifications and battery pack position.

[0111] The bonding type refers to the bonding installation method between the power distribution unit and the battery pack, as defined by the technicians. The bonding surface refers to the surface of the power distribution unit that is in contact with the battery pack. This bonding surface is selected from the driving model and used as the bonding surface.

[0112] S24: Obtain the housing manufacturing parameters based on the bonding surface.

[0113] Since heat dissipation air cannot easily enter the cavity 3 inside the LDS lower housing assembly 1 from the bonding surface when the bonding surface is bonded to the battery pack, the housing manufacturing parameters are matched from the preset manufacturing database according to the aspect where the bonding surface is located.

[0114] The manufacturing database stores the shell manufacturing parameters corresponding to the bonding surfaces in different orientations. The bonding surfaces in each shell manufacturing parameter do not have heat dissipation structures (such as heat dissipation holes). The parameters in the manufacturing database are set in advance by those skilled in the art based on the actual situation, and will not be elaborated here.

[0115] Methods for obtaining manufacturing parameters also include:

[0116] S30: Combining the flow direction with the reference specifications to obtain the design type of copper busbar assembly 6.

[0117] The design type refers to the type of flow guiding structure design of the copper busbar assembly 6 when it is installed at the copper busbar installation position (such as "single-sided flow guide wing", "double-sided flow guide array", "central turbulence protrusion", "changing the angle of the non-contact area by using additive manufacturing or grinding", etc.). The design type is matched from the preset design reference table by the flow guiding direction and the reference specifications.

[0118] The design reference table stores the design types corresponding to different flow directions and reference specifications. The parameters in the design reference table are set in advance by those skilled in the art based on actual conditions and will not be elaborated here.

[0119] S31: Obtain the variation part by designing the type and the reference specification.

[0120] The variable part refers to the part of the copper busbar assembly 6 that differs from the copper busbar assembly 6 of the standard specification. For example, when the design type is "single-sided guide vane", the variable part is the designated side of the non-contact functional area of ​​the copper busbar assembly 6. The variable part can be located by analyzing the structural features required by the design type and comparing them with the three-dimensional model of the copper busbar assembly 6 of the standard specification.

[0121] S32: Update the driving model based on the changed parts.

[0122] The copper busbar component 6 in the driving model is regenerated into new driving models according to different design types and corresponding changes.

[0123] S33: Retrieve the operating power value and reference current from the vehicle type, and simulate the driving model using the operating power value.

[0124] The operating power value refers to the power output by the battery pack when the vehicle is running, and the reference carrying current refers to the current threshold that the copper busbar assembly 6 needs to operate stably for a long time. By retrieving the operating power value and the reference carrying current from the vehicle type, and using the operating power value as the input condition, the updated driving model is subjected to electro-thermal coupling simulation to simulate the working state of the power distribution unit under real load.

[0125] S34: Retrieve the actual carrying current from the driving model.

[0126] The actual carrying current refers to the actual current value flowing through the copper busbar assembly 6 in the simulated driving model. The actual carrying current is obtained by retrieving it from the simulated driving model.

[0127] S35: Compare the actual carrying current with the reference carrying current to update the design type in case of exceedance.

[0128] A new design type is selected by analyzing the actual carrying current and the reference carrying current. The new design type will not affect the use of the original power distribution unit.

[0129] S36: Manufacturing parameters are obtained based on the design type and baseline specifications.

[0130] The specifications of copper busbar assembly 6 are updated according to the design type and baseline specifications to obtain new manufacturing parameters.

[0131] Validation methods for design types include:

[0132] S40: The heat dissipation rate inside the shell is obtained based on heat dissipation parameters and airflow direction inside the shell.

[0133] The internal heat dissipation rate refers to the amount of heat lost through convection in the cavity 3 of the power distribution unit per unit time. It can be calculated using CFD simulation results, with the formula: Internal heat dissipation rate = h * A * ΔT, where h is the convective heat transfer coefficient, A is the heat dissipation area, and ΔT is the temperature difference. These parameters can be extracted from the heat dissipation parameters and the airflow direction within the shell. The analysis and calculation methods for the internal heat dissipation rate are common knowledge to those skilled in the art and will not be elaborated here.

[0134] S41: Based on the design type, operating power value, and driving model, the marked output heat is obtained.

[0135] The marked output heat refers to the total heat generated by the power distribution unit of the design type under the operating power value. Using the operating power value as input, the Joule heat of the copper busbar assembly 6 is obtained through electro-thermal simulation of the driving model corresponding to each design type, and is used as the marked output heat. The method for obtaining the marked output heat is common knowledge to those skilled in the art and will not be elaborated here.

[0136] S42: The baseline output heat is obtained by using the baseline specifications, operating power values, and driving model.

[0137] The baseline output heat refers to the total heat generated by the power distribution unit of the baseline specification under the operating power value. The baseline output heat is obtained by electro-thermal simulation of the driving model corresponding to the baseline specification with the operating power value as the input condition, referring to S41.

[0138] S43: The rate of heat change is obtained by comparing the output heat from the marked source with the baseline output heat.

[0139] The rate of change of heat refers to the rate of change of heat due to changes in design type, which is obtained by calculating the difference between the marked output heat and the baseline output heat.

[0140] If the rate of change of heat is negative, it indicates that the heat generation is reduced due to the design type.

[0141] S44: Compare the internal heat dissipation rate with the rate of thermal change to update the design type.

[0142] When the rate of heat change exceeds the rate of heat dissipation within the shell, it indicates that the design type generates its own heat while increasing the rate of heat dissipation within the shell, which also exceeds the increased rate of heat dissipation within the shell. Therefore, design types with a rate of heat change exceeding the rate of heat dissipation within the shell should be eliminated.

[0143] When the rate of heat change does not exceed the rate of heat dissipation inside the shell, it indicates that the design type has its own heat increasing or decreasing simultaneously when the rate of heat dissipation inside the shell is increased, but does not exceed the increased rate of heat dissipation inside the shell. Therefore, the difference between the rate of heat dissipation inside the shell and the rate of heat change is calculated, and the design types are sorted from largest to smallest according to the difference (prioritizing the design with the greatest heat reduction) for subsequent operators to choose from.

[0144] Methods for updating design types include:

[0145] S50: Determine whether the actual carrying current exceeds the reference carrying current.

[0146] By determining whether the actual carrying current exceeds the reference carrying current, it is possible to determine whether there are any factors affecting the performance of the copper busbar assembly 6 in the power distribution unit within each design type.

[0147] S51: When the actual carrying current exceeds the reference carrying current, continue to output the design type.

[0148] When the actual carrying current exceeds the reference carrying current, it indicates that none of the design types have affected the performance of the copper busbar assembly 6.

[0149] S52: When the actual carrying current does not exceed the reference carrying current, the difference between the actual carrying current and the reference carrying current is calculated as the deviation carrying current.

[0150] Deviation carrying current refers to the deviation between the actual carrying current, which does not exceed the reference carrying current, and the reference carrying current.

[0151] When the actual carrying current does not exceed the reference carrying current, it indicates that there is a design type that affects the performance of copper busbar assembly 6. The difference between the actual carrying current and the reference carrying current of this design type is then calculated as the deviation carrying current.

[0152] S53: Based on the deviation carrying current and design type, the change size of the variable part is obtained.

[0153] The variable dimension refers to the dimension of the changed part that needs to be compensated to meet the performance of the copper busbar assembly 6. The variable dimension of the changed part is matched from the design reference table by the deviation carrying current and the corresponding design type. For example, if the design type is "use additive manufacturing or grinding to change the angle of the non-contact area", then the size of the angle needs to be adjusted.

[0154] The design comparison table also stores the different deviation currents and the corresponding change dimensions of the different parts for different design types, which will not be elaborated here.

[0155] S54: Update the design type based on the changing dimensions.

[0156] A new design type is obtained by replacing the original size of the changed part of the design type with a different size.

[0157] Other methods for updating design types include:

[0158] S60: Retrieve the baseline process from the baseline specification.

[0159] The reference process refers to the conventional processing methods and parameters used to manufacture the copper busbar assembly 6 in the reference specification. The reference process is obtained by retrieving the reference specification, such as injection molding, welding and grinding.

[0160] S61: Update the baseline process by changing the dimensions, and obtain the anomaly type based on the baseline process.

[0161] Anomaly types refer to those that are prone to occur during the baseline process due to dimensional changes in the changed parts. For example, when the thickness of the copper busbar guide vane decreases from 3mm to 0.8mm, the system identifies the anomaly type as "thin-wall warping." When the guide angle is less than 15°, it is identified as "insufficient filling of sharp angles during injection molding." The anomaly type is matched by inputting the baseline process into the design lookup table.

[0162] The design comparison table also stores the anomaly types corresponding to different baseline processes under different manufacturing dimensional parameters, which will not be elaborated here.

[0163] S62: To create a manufacturing model based on the baseline process, design type, and baseline specifications.

[0164] A manufacturing model refers to a three-dimensional process model that integrates component structural parameters (design type, baseline specifications) and machining process parameters (baseline process). It is used to simulate the entire production process and verify process feasibility. By importing the steps and parameters of the baseline process, the structural data of the design type, and the material and tolerance requirements of the baseline specifications into integrated CAD / CAM software (such as UGNX), a three-dimensional model containing process information (such as machining sequence, toolpaths, and welding points) is constructed. Integrated CAD / CAM modeling functionality is existing technology in this field and will not be elaborated upon here. In this embodiment, one design type corresponds to one manufacturing model.

[0165] S63: Retrieve process quantities from the production model.

[0166] The number of processes refers to the number of processes required to complete the copper busbar component 6 corresponding to the design type, which is obtained by retrieving the number of processes from the manufacturing model.

[0167] S64: Obtain the anomaly weight score based on the production model, number of processes, and anomaly type.

[0168] Anomaly weight score refers to a score used to quantify the degree of anomaly in the manufacturing model of a design type (the score ranges from 0 to 10 points, with higher scores indicating more severe process risks). Based on the anomaly type, process parameter thresholds (such as a 5° threshold for grinding the flow guide side in the absence of anomalies) and corresponding weight scores are matched from the design reference table. The actual process value is retrieved from the manufacturing model (the angle for grinding the flow guide side needs to be 15°). The difference between the actual process value and the process parameter threshold is calculated to obtain the anomaly deviation. Then, based on the anomaly deviation, a correction coefficient is matched from the design reference table. The product of the correction coefficient and the weight score is calculated to obtain a new weight score.

[0169] Abnormal weight score = Σ (weight score × proportion of corresponding process step).

[0170] The percentage of corresponding process steps = the number of steps corresponding to the exception type retrieved from the production model / the number of processes.

[0171] In this embodiment, the weight setting and calculation method for different abnormality types in the design comparison table are common knowledge to those skilled in the art and are set in advance, and will not be described in detail here.

[0172] S65: The rate deviation value is calculated as the difference between the heat dissipation rate inside the shell and the rate of heat change, depending on the design type.

[0173] The rate deviation value refers to the deviation between the heat dissipation rate inside the shell and the rate of heat change. It is calculated as the difference between the heat dissipation rate inside the shell and the rate of heat change for the corresponding design type.

[0174] S66: Obtain a comprehensive weight score by combining the abnormal weight score with the rate deviation value, and update the design type with the highest comprehensive weight score.

[0175] The comprehensive weight score is a combined evaluation score that combines process feasibility (abnormal weight score) and heat dissipation matching (rate deviation value) to select the optimal design type (score range 0-10 points). The scoring formula is: Comprehensive weight score = (10 - abnormal weight score) × 0.6 + max(rate deviation value / baseline heat dissipation rate × 10, 0) × 0.4.

[0176] Among them, the benchmark heat dissipation rate is the in-case heat dissipation rate corresponding to the benchmark specification (retrieved from the benchmark specification), 0.6 and 0.4 are the weighting coefficients of process feasibility and heat dissipation matching (preset by those skilled in the art based on product design priorities), and the max function ensures that this part scores 0 when heat dissipation is insufficient.

[0177] By calculating the comprehensive weight score of different design types, the design type with the highest score is selected as the final updated design type. The scoring formula and optimization selection method are common knowledge to those skilled in the art and are pre-set, so they will not be elaborated here.

[0178] Methods for verifying abnormal weight scores include:

[0179] S70: Retrieve the abnormal process part of the abnormal type from the production model.

[0180] Abnormal process parts refer to specific process steps or component structure areas in the manufacturing model where abnormal types occur. Abnormal process parts of abnormal types can be retrieved from the manufacturing model. For example, in the design type of copper busbar component 6, the included angle between components changes from the original 90° to 60°, resulting in an abnormal type of insufficient filling of acute angles in the injection molding process. In this case, the included angle between components is regarded as an abnormal process part.

[0181] S71: Obtain the split-and-combination process by comparing abnormal process parts with the baseline process, and update the manufacturing model with the split-and-combination process.

[0182] The split-and-combination process refers to breaking down the formation of abnormal process parts into multiple processes and combining them to generate the model. By structurally splitting the abnormal process parts according to their characteristics, manufacturing the corresponding split baseline process after structural splitting, and combining the split structure according to other processes, the split baseline process and the combined process are used as the split-and-combination process. The split-and-combination process replaces the baseline process of the abnormal process parts to regenerate a new manufacturing model.

[0183] For example, the process of molding an angle in one injection can be broken down into two injections to obtain two plates, and then the two plates are welded together to form the angle. Therefore, the abnormal process part changes from the total injection to injection and welding, which is a separate and combined process.

[0184] S72: Retrieve abnormal dimensional parameters of abnormal process parts from the design type.

[0185] Abnormal dimensional parameters refer to the dimensional parameters of abnormal process parts, which are retrieved from the design type.

[0186] S73: Obtain the combination anomaly type based on the splitting and combining process.

[0187] The combination anomaly type refers to the anomaly type of the split and combined process. Refer to S61 and use the matching anomaly type from the split and combined process input design comparison table as the combination anomaly type.

[0188] S74: Combine the combined anomaly type with the model and anomaly size parameters to obtain the combined weight score.

[0189] The combination weight score refers to the abnormal weight score of the new manufacturing model in the splitting and assembly process. The abnormal weight score obtained by analyzing and calculating the combination abnormality type, manufacturing model and abnormal size parameters with reference to S64 is used as the combination weight score.

[0190] S75: Update abnormal weight scores based on combined weight scores.

[0191] The combined weight score replaces the base process weight score of the abnormal process location and is recalculated to obtain a new abnormal weight score. For example, the weight score of a one-time injection molding is 6 points (when only one injection molding step is replaced, the corresponding process step accounts for 1), while the combined weight score is 4 points (refer to S71, which combines injection molding and welding steps). The weight score of the one-time injection molding is replaced with the combined weight score, and the abnormal weight score is recalculated with the combined weight score of 4 points, referring to S64, to obtain a new abnormal weight score.

[0192] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional modules is used as an example. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the internal structure of the device can be divided into different functional modules to complete all or part of the functions described above. The specific working process of the system, device, and unit described above can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0193] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A method for manufacturing a battery pack power distribution unit, characterized in that, include: S10: Collect the baseline specifications of the vehicle type and power distribution unit; S11: Retrieve the installation location of the power distribution unit from the vehicle type; S12: Obtain a driving model by determining the installation location, baseline specifications, and vehicle type; S13: Based on the driving model to generate heat dissipation parameters; S14: Retrieve the installation components of the power distribution unit from the reference specifications; S15: Obtain the shell manufacturing parameters based on the vehicle type, driving model, and mounting components; S16: The airflow direction inside the casing is obtained by combining heat dissipation parameters and casing manufacturing parameters; S17: Retrieve the heating location and the copper busbar installation position of the copper busbar assembly (6) from the driving model; S18: The transmission direction is determined based on the heating location and the copper busbar installation location; S19: Combine the transmission direction with the wind direction inside the shell to obtain the guiding direction; S110: Obtain the manufacturing parameters of the copper busbar assembly (6) through the flow direction and reference specifications, add the housing manufacturing parameters to the manufacturing parameters of the copper busbar assembly (6), and upload and output the manufacturing parameters of the copper busbar assembly (6).

2. The method for manufacturing a battery pack power distribution unit according to claim 1, characterized in that, Methods for obtaining the casing manufacturing parameters include: S20: Retrieve installation specifications from vehicle type; S21: Retrieve the battery pack location from the driving model; S22: The installation type of the power distribution unit is obtained by the installation specifications and the location of the battery pack; S23: When the installation type is the preset bonding type, the bonding surface is obtained based on the driving model, installation specifications and battery pack position; S24: Obtain the housing manufacturing parameters based on the bonding surface.

3. The method for manufacturing a battery pack power distribution unit according to claim 1, characterized in that, The method for obtaining the manufacturing parameters of the copper busbar assembly (6) further includes: S30: Combine the flow direction with the reference specifications to obtain the design type of the copper busbar assembly (6); S31: The variation parts of the copper busbar assembly (6) are obtained by using the design type and reference specifications of the copper busbar assembly (6); S32: Update the driving model according to the changes in the copper busbar assembly (6); S33: Retrieve the operating power value and reference current carrying capacity from the vehicle type, and simulate the driving model using the operating power value; S34: Retrieve the actual current carrying capacity from the driving model; S35: Compare the actual carrying current with the reference carrying current to update the design type of the copper busbar assembly (6); S36: The manufacturing parameters of the copper busbar assembly (6) are obtained according to the design type and reference specifications of the copper busbar assembly (6).

4. The method for manufacturing a battery pack power distribution unit according to claim 3, characterized in that, The verification method for the design type of the copper busbar assembly (6) includes: S40: The heat dissipation rate inside the shell is obtained based on heat dissipation parameters and airflow direction inside the shell. S41: Based on the design type, operating power value and driving model of the copper busbar assembly (6), the marked output heat is obtained; S42: The baseline output heat is obtained by using the baseline specifications, operating power values, and driving model; S43: Obtain the rate of heat change by comparing the marked output heat with the reference output heat; S44: Compare the internal heat dissipation rate with the rate of change of heat to update the design type of the copper busbar assembly (6).

5. The method for manufacturing a battery pack power distribution unit according to claim 3, characterized in that, The method for updating the design type of the copper busbar assembly (6) includes: S50: Determine whether the actual carrying current exceeds the reference carrying current; S51: When the actual carrying current exceeds the reference carrying current, continue to output the design type of the copper busbar assembly (6); S52: When the actual carrying current does not exceed the reference carrying current, the difference between the actual carrying current and the reference carrying current is calculated as the deviation carrying current; S53: Based on the deviation carrying current and the design type of the copper busbar assembly (6), the change size of the change part of the copper busbar assembly (6) is obtained; S54: Update the design type of the copper busbar assembly (6) according to the change in size.

6. The method for manufacturing a battery pack power distribution unit according to claim 5, characterized in that, The method for updating the design type of the copper busbar assembly (6) further includes: S60: Retrieve the baseline process from the baseline specification; S61: Update the baseline process by changing the dimensions, and obtain the anomaly type of the copper busbar assembly (6) based on the baseline process; S62: Based on the reference process, the design type of the copper busbar assembly (6) and the reference specifications, a manufacturing model of the copper busbar assembly (6) is formed; S63: Retrieve the process quantity from the manufacturing model of the copper busbar assembly (6); S64: Obtain an anomaly weight score based on the manufacturing model, process quantity, and anomaly type of the copper busbar assembly (6); S65: The difference between the heat dissipation rate inside the case and the heat change rate is calculated as the rate deviation value according to the design type of the copper busbar assembly (6); S66: Obtain a comprehensive weight score by using the abnormal weight score and the rate deviation value, and update the design type of the copper busbar assembly (6) with the maximum comprehensive weight score.

7. The method for manufacturing a battery pack power distribution unit according to claim 6, characterized in that, Methods for verifying abnormal weight scores include: S70: Retrieve the abnormal process part of the abnormal type of the copper busbar assembly (6) from the manufacturing model of the copper busbar assembly (6); S71: Obtain the split-and-combination process by comparing the abnormal process parts with the baseline process, and update the manufacturing model of the copper busbar assembly (6) with the split-and-combination process; S72: Retrieve the abnormal dimension parameters of the abnormal process part from the design type of the copper busbar assembly (6); S73: Based on the splitting and combining process, the combination anomaly type of copper busbar assembly (6) is obtained; S74: Combine the combination anomaly type of the copper busbar assembly (6) with the manufacturing model of the copper busbar assembly (6) and the anomaly size parameters to obtain the combination weight score; S75: Update abnormal weight scores based on combined weight scores.

8. A battery pack power distribution unit, employing the manufacturing method of a battery pack power distribution unit as described in any one of claims 1 to 7, characterized in that, The device includes an LDS lower housing assembly (1), a bottom protective cover (2) connected to the LDS lower housing assembly (1) to form a cavity (3), a relay (4) located in the cavity (3) and connected to the LDS lower housing assembly (1), a PCBA board (5) connected to the LDS lower housing assembly (1) and used to control the opening and closing of the relay (4), and a copper busbar assembly (6) connected to the relay (4) and used to assist the PCBA board (5) in controlling the opening and closing of the relay (4). The LDS lower housing assembly (1) is provided with a control line (7) for connecting the relay (4) and the PCBA board (5). A metal spring (8) is provided between the copper busbar assembly (6) and the LDS lower housing assembly (1).

9. A battery pack power distribution unit according to claim 8, characterized in that, Three copper busbar assemblies (6) are provided. The copper busbar assemblies (6) on the relay (4) are respectively connected to the positive and negative terminals of the battery pack. Another copper busbar assembly (6) is located between the PCBA board (5) and the LDS lower housing assembly (1). The relay (4) is provided with a partition (9) to prevent the high voltage arc generated by the copper busbar assembly (6) from directly breaking down the air to form a short circuit.

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