A power distribution unit and a charging device

Abstract

This invention provides a power distribution unit and a charging device. The power distribution unit includes: a plurality of distribution components arranged sequentially along a first direction; each distribution component includes a circuit board and a plurality of onboard relays; the circuit board extends along a second direction, and each onboard relay is disposed on the circuit board; the second direction is perpendicular to the first direction; a bus assembly including a plurality of first busbars and a plurality of second busbars, the first busbars crossing at least one distribution component and connecting one end of each onboard relay located in different distribution components, the second busbars connecting the other end of each onboard relay located in the distribution component to connect or disconnect current loops through the onboard relays; an outer frame including at least two side frames arranged along the second direction; the two ends of the circuit board in the distribution component along the second direction are inserted and fixed to the corresponding side frames along a third direction. This power distribution unit has the advantages of small size, low cost, and convenient maintenance.

Description

Technical Field

[0001] This invention relates to the field of power distribution technology, specifically to a power distribution unit and a charging device. Background Technology

[0002] With the rapid development of the electric vehicle industry, the market demand for high-power DC charging piles is increasing. To improve the utilization rate of charging modules, modern charging piles typically employ dynamic power allocation technology, also known as flexible allocation or matrix switching. This technology flexibly allocates the power of the charging module to different charging guns based on the real-time charging needs of different vehicles. In existing technical solutions, this power matrix switching mainly relies on traditional high-voltage DC contactors, which are typically large cylindrical contactors. In a typical charging system with multiple outputs, a large number of relays or contactors are often required to enable the switching function of any charging module to any charging gun. For example, in certain 12-gun full matrix topologies, up to 130 or more switching devices may be needed. Due to the large size and large number of contactors, this power distribution unit is bulky, costly, and difficult to maintain. Summary of the Invention

[0003] The purpose of this invention is to overcome the above-mentioned defects or problems in the prior art and to provide a power distribution unit and a charging device, which have the advantages of small size, low cost and convenient maintenance.

[0004] To achieve the above objectives, the present invention adopts the following technical solution:

[0005] Technical Solution 1: A power distribution unit, comprising: a plurality of distribution components, each of the distribution components being arranged sequentially along a first direction; each distribution component including a circuit board and a plurality of onboard relays; the circuit board extending along a second direction, each of the onboard relays being disposed on the circuit board; the second direction being perpendicular to the first direction; a bus component including a plurality of first busbars and a plurality of second busbars, the first busbars spanning at least one of the distribution components connecting one end of each of the onboard relays located in different distribution components, the second busbars connecting the other end of each of the onboard relays located in the distribution component, so as to connect or disconnect current loops through the onboard relays; an outer frame, comprising at least two side frames arranged along the second direction; the two ends of the circuit board in the distribution component along the second direction being inserted and fixed to the corresponding side frames along a third direction; the third direction being perpendicular to the first direction and the second direction.

[0006] Technical Solution 2 based on Technical Solution 1: Each of the onboard relays in the distribution component is disposed on the circuit board along the second direction.

[0007] Technical Solution 3 based on Technical Solution 2: In the bus assembly, at least a portion of the first bus extends along a first direction to connect the onboard relay corresponding to the position along the first direction across the distribution assembly, and at least a portion of the second bus extends along a second direction to connect the onboard relay disposed along the second direction within the distribution assembly.

[0008] Technical Solution 4 based on Technical Solution 3: In the distribution component, the board surface of the circuit board is parallel to the third direction, and latching terminals are provided on both sides of each onboard relay along the third direction. The onboard relay is used to control the on / off state of the corresponding two latching terminals. The first bus and the second bus in the bus assembly are respectively connected to the latching terminals on both sides of the onboard relay.

[0009] Technical Solution 5 based on Technical Solution 4: In the bus component, the first bus and the second bus are respectively located on both sides of the distribution component along the third direction; the side where the first bus is located is defined as the first side of the third direction, and the side where the second bus is located is defined as the second side of the third direction.

[0010] Technical solution six based on technical solution five: The side frame is provided with a sliding groove corresponding to each of the circuit boards and extending along a third direction. The circuit board is at least adapted to be inserted into the sliding groove toward the first side along the third direction and fixed in the first direction; the outer frame also includes a limiting baffle, which is detachably fixed to the second side of the side frame along the third direction and adapted to block the opening of the sliding groove on the second side along the third direction.

[0011] Technical solution seven based on technical solution six: The opening of the second side of the slide along the third direction is in the shape of an outwardly flared trumpet.

[0012] Technical solution eight based on technical solution one: The outer frame further includes a top frame and a bottom frame; the top frame and the bottom frame extend along the second direction and respectively connect the top and bottom of the two side frames.

[0013] Technical solution nine based on technical solution eight: further includes at least one reinforcing member; the reinforcing member extends along a first direction, one end of which is fixed to the top frame and / or bottom frame, and the other end spans several of the distribution components and is fixed to the second busbar.

[0014] Furthermore, the present invention also provides technical solution ten: a charging device for charging multiple loads, comprising a power distribution unit as described in any one of technical solutions one to nine; a plurality of charging modules adapted to be connected to a power supply and provide matching electrical energy to the loads; and a wiring component connecting the power distribution unit and each of the charging modules, and having a wiring terminal corresponding to each of the loads; each first busbar in the power distribution unit is connected to the charging module through the wiring component, so as to distribute the electrical energy provided by the charging module to the load to at least one of the wiring terminals by switching on and off the onboard relays in the distribution component.

[0015] As can be seen from the above description of the present invention, compared with the prior art, the present invention has the following beneficial effects:

[0016] Technical Solution 1 provides a power distribution unit, which includes several distribution components arranged sequentially along a first direction. These components include a circuit board extending along a second direction and several onboard relays. By replacing the high-voltage DC contactors in a conventional power distribution unit with onboard relays, the miniaturization advantage of onboard relays is utilized, initially reducing the size of the power distribution unit and lowering the overall manufacturing cost. Simultaneously, the distribution components are stacked along the first direction, effectively utilizing the cabinet space in that direction and ensuring that the distance between onboard relays in adjacent distribution components is approximately the same, facilitating the interconnection of onboard relays in different distribution components. Furthermore, the power distribution unit includes a bus assembly, comprising a first bus and a second bus, which are used to interconnect onboard relays in different distribution components and onboard relays within the same distribution component, respectively. Combined with the structure of the onboard relays mounted on the circuit board, the overall bus path is clear, and the switching path is more clearly defined when constructing a flexible switching topology. Furthermore, since the onboard relays are connected through this busbar assembly, the number of onboard relays in each distribution assembly can be set to be the same. This ensures that the configuration of each distribution assembly is identical, further improving the standardization of the distribution assembly design and manufacturing, thereby reducing the overall design and manufacturing cost. Moreover, this power distribution unit is more convenient to maintain than conventional power distribution units using high-voltage DC contactors. Because the onboard relays are all mounted on the circuit board, and the circuit board is fixed to the side frame of the outer frame via plug-in connections, when maintenance or replacement of the onboard relays is required, the connection between the corresponding locked first and second busbars in the busbar assembly and the distribution assembly can be removed. The distribution assembly can then be directly pulled out of the side frame, allowing for convenient maintenance and repair of the onboard relays or circuit board. Therefore, this power distribution unit has the advantages of smaller size, lower cost, and easier maintenance compared to conventional power distribution units using high-voltage DC contactors.

[0017] In technical solution two, the onboard relays are arranged linearly along the length of the circuit board, so that the onboard relays in the distribution components form a one-dimensional array in space. This arrangement matches the structure of the circuit board and allows all the onboard relays to form a regular two-dimensional array distribution in the planes of the first and second directions after the distribution components are stacked in the first direction. This simplifies the path planning and layout of the subsequent bus components, avoids the messy distribution and detours of the bus components, enables standardized assembly, and facilitates the disassembly and maintenance of the distribution components.

[0018] In technical solution three, the extension paths of the first and second busbars are limited. By utilizing the layout of onboard relays, the busbars responsible for cross-component connections and those responsible for intra-component connections are naturally separated in physical path. This reduces spatial interference between buses at different potentials, thereby reducing the need for complex insulation and isolation structures. It also makes the distribution of electrical connection points more regular, facilitating automated assembly and manual maintenance.

[0019] In technical solution four, latching terminals are respectively set on both sides of the onboard relay on the circuit board, and the first and second busbars are connected to the latching terminals to facilitate the installation of the bus assembly and avoid spatial interference between the bus assembly and the circuit board.

[0020] In technical solution five, the first bus and the second bus are respectively set on both sides of the distribution component, so that one side of the distribution component has only the first bus and the other side has only the second bus. When maintenance and repair of a certain distribution component is required, the distribution component can be pulled out from the side with the horizontal second bus, without worrying about being affected by the vertical first bus, thus greatly facilitating the maintenance and repair of the distribution component.

[0021] In technical solution six, a sliding groove and a detachable limiting baffle are provided on the side frame. The sliding groove can be used to fix the distribution component, and the limiting baffle can prevent the distribution component from coming out of the sliding groove. When maintenance is required, the distribution component can be taken out of the sliding groove simply by removing the limiting baffle, without disassembling the entire outer frame, which facilitates the maintenance and repair of the distribution component.

[0022] In technical solution seven, the opening of the slide is set to a horn shape, so that the circuit board can be guided through the opening of the slide during the insertion process, which facilitates the insertion of the circuit board into the slide and avoids collision between the circuit board and the outer frame, thus protecting the circuit board.

[0023] In technical solution eight, a top frame and a bottom frame are set to connect the two side frames, so that the outer frame forms a closed rectangular frame structure, which significantly improves the structural stability and strength of the overall outer frame and ensures that the outer frame will not deform when bearing the distribution component and the bus component.

[0024] In technical solution nine, reinforcing components are installed to avoid the problem of insufficient rigidity of long-span circuit boards or busbars, and to prevent large deformation of circuit boards or busbars in the middle position, thereby ensuring that the circuit board will not be torn by stress and improving the reliability of the power distribution unit.

[0025] Technical solution ten provides a charging device. Due to the use of the power distribution unit, the internal space utilization of the charging device is greatly improved, the overall manufacturing cost is reduced, and the maintenance cost of the power distribution unit is reduced. Attached Figure Description

[0026] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments are 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.

[0027] Figure 1 This is an exploded view of the power distribution unit according to an embodiment of the present invention;

[0028] Figure 2 This is an exploded view of a portion of the power distribution unit involved in an embodiment of the present invention;

[0029] Figure 3 This is a schematic diagram of the power distribution unit according to an embodiment of the present invention along a third direction to the first side;

[0030] Figure 4 This is a schematic diagram of the power distribution unit along a third direction to the second side according to an embodiment of the present invention;

[0031] Figure 5 This is a schematic diagram of the distribution component in the power distribution unit according to an embodiment of the present invention;

[0032] Figure 6 This is a schematic diagram of the allocation component involved in an embodiment of the present invention. Figure 1 ;

[0033] Figure 7 This is a schematic diagram of the allocation component involved in an embodiment of the present invention. Figure 2 ;

[0034] Figure 8 This is a schematic diagram of the allocation component involved in an embodiment of the present invention. Figure 3 ;

[0035] Figure 9 This is a power flexible allocation matrix topology involved in an embodiment of the present invention.

[0036] Explanation of key figure labels:

[0037] Distribution component 100; circuit board 110; slot 111; first slot 112; second slot 113; onboard relay 120; relay connection terminal 121; latching terminal 130; component group 140;

[0038] Busbar assembly 200; First busbar 210; Second busbar 220; Connector 230;

[0039] Outer frame 300; side frame 310; slide groove 311; slide groove opening 312; slide rail 313; top frame 320; bottom frame 330; limiting plate 340;

[0040] Reinforcing component 400. Detailed Implementation

[0041] 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 preferred embodiments of the present invention and should not be considered as excluding other embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0042] Unless otherwise expressly defined, the use of terms such as "first," "second," or "third" in the claims, description, and accompanying drawings of this invention is for distinguishing different objects and not for describing a specific order.

[0043] Unless otherwise expressly defined, in the claims, description, and accompanying drawings of this invention, the use of directional terms such as "center," "lateral," "longitudinal," "horizontal," "vertical," "top," "bottom," "inner," "outer," "upper," "lower," "front," "rear," "left," "right," "clockwise," and "counterclockwise" to indicate orientation or positional relationships is based on the orientation and positional relationships shown in the accompanying drawings and is only for the convenience of describing the invention and simplifying the description, and is not intended to indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as limiting the specific scope of protection of this invention.

[0044] Unless otherwise expressly defined, the terms "fixed connection" or "fixed connection" used in the claims, description and drawings of this invention should be interpreted broadly to refer to any connection in which there is no displacement or relative rotation relationship between the two parties, including non-removable fixed connection, detachable fixed connection, integral connection and fixed connection by other means or components.

[0045] In the claims, description and accompanying drawings of this invention, the terms "comprising," "having," and variations thereof are used to mean "including but not limited to."

[0046] Example 1

[0047] Embodiment 1 of this invention relates to a charging device for charging multiple loads, which may be charging guns used to charge new energy electric vehicles that require charging. The charging device includes a power distribution unit provided by this invention, as well as several charging modules and wiring components.

[0048] The charging module is designed to connect to a power supply and provide matching electrical energy to the load. Specifically, as the core unit of power conversion, the charging module's input is connected to the AC power grid (such as 380V AC), primarily used to convert AC power into high-voltage DC power. Since different models of electric vehicles with varying remaining battery levels have vastly different charging power requirements (e.g., some only require 20kW slow charging, while others require 480kW supercharging), using a fixed "one charger, one gun" configuration would result in low utilization of the charging module. Therefore, the charging equipment in this embodiment adopts a flexible power distribution architecture.

[0049] The wiring component connects the power distribution unit and each charging module, and has terminals corresponding to each load. As the output terminal, the wiring component has multiple terminals (e.g., for connecting to multiple charging guns), each terminal corresponding to a load to be charged. The power distribution unit is positioned between the charging modules and the wiring component, serving as the core actuator of the power switching matrix. The connection relationship between the wiring component and the power distribution unit is described in detail below.

[0050] In this architecture, the DC power output from the charging modules is not directly transmitted to the load, but rather first fed into the power distribution unit. The control system, based on real-time charging demands from each load (such as BMS messages), controls the power distribution unit to flexibly switch the power of one or more charging modules to designated terminals. For example, when a load requires high-power charging, the power distribution unit can connect the outputs of multiple charging modules in parallel and then supply them to the corresponding terminal of that load; when multiple loads are charging simultaneously, the power of different charging modules is independently allocated to each terminal, achieving dynamic power sharing and on-demand distribution.

[0051] The structure of the power distribution unit will now be described in detail.

[0052] Reference Figures 1 to 4 The power distribution unit includes several distribution components 100, a busbar assembly 200, an outer frame 300, and a reinforcing member 400.

[0053] Before further describing the power distribution unit, it is necessary to explain the relevant directions in the specification and claims of this invention. The first, second, and third directions in the specification and claims of this invention are mutually orthogonal and perpendicular directions. In this embodiment, referring to the accompanying drawings, they are respectively referred to as the up-down direction, left-right direction, and front-back direction.

[0054] First, let's explain the allocation component 100. (Refer to...) Figure 5 Each distribution component 100 is stacked sequentially along a first direction, thereby making full use of the cabinet's height space. Each distribution component 100 mainly includes a circuit board 110, several onboard relays 120, and several sets of latching terminals 130. The circuit board 110, as the main supporting body, is elongated and extends along a second direction perpendicular to the first direction. Several onboard relays 120 are linearly arranged on the circuit board 110 at predetermined intervals along the second direction, forming a regular one-dimensional array in space. This layout ensures that when multiple distribution components 100 are stacked along the first direction, all onboard relays 120 form a matrix distribution in the side view plane, facilitating circuit planning.

[0055] To enable the connection and disconnection of large external currents, the circuit board 110 is provided with latching terminal groups 130 corresponding to each onboard relay 120. These latching terminal groups 130 are arranged at predetermined intervals along a second direction. Each latching terminal group 130 includes two latching terminals 130, which are arranged on both sides of the onboard relay 120 along a third direction perpendicular to both the first and second directions. The contacts of the onboard relay 120 are connected in series between the corresponding two latching terminals 130 to control the on / off state of the current loop between them.

[0056] The busbar assembly 200 in this power distribution unit typically uses a heavy copper busbar, and it needs to be latched to the latching terminal 130 in the distribution assembly 100. Multiple connections can easily accumulate manufacturing tolerances; if the copper busbar is directly latched to the rigid circuit board 110, it can easily cause the circuit board 110 to twist or the solder joints to crack. Therefore, refer to... Figure 6The circuit board 110 has several inwardly extending slots 111 on at least one edge along a third direction. Here, "inwardly extending" refers to extending from one edge of the circuit board 110 along the third direction toward the other edge. Specifically, at least one slot 111 is provided between two adjacent latching terminals 130 along the second direction. This slot 111 penetrates the thickness direction of the circuit board 110, thereby physically dividing the originally continuous edge structure of the circuit board 110 into several relatively independent cantilever structures, on which the aforementioned latching terminals 130 are fixed. Through this slot 111 design, the cantilever area where the latching terminals 130 are located is decoupled from the central body of the circuit board 110 in terms of force. When the bus assembly 200 is connected to the latching terminals 130, if there is a small positional deviation or flatness tolerance, the cantilever can adaptively compensate by undergoing moderate micro-deformation using the elasticity of the material itself, without transmitting huge mechanical stress to the main body of the circuit board 110 or the solder pins of the onboard relay 120.

[0057] Preferred, refer to Figure 6 The bottom of the slot 111 extends to a depth inside the circuit board 110, and is set to be closer to the inner center line of the circuit board 110 than the connection position of the latching terminal 130. See the attached diagram for details. Figure 6 The positional difference between the two is indicated by the red dashed line. This depth setting cuts off the direct inward transmission path of stress, forcing the stress to bypass the root of slot 111, further protecting the reliability of the electrical connection point.

[0058] In this embodiment, the circuit board 110 has slots 111 on both sides of its third-direction edges, forming a plurality of slot groups 111. To address the uneven stress caused by the possibility of connecting different busbar specifications on both sides of the circuit board 110 (e.g., one side connecting a vertical busbar across a component, and the other side connecting a horizontal busbar within the component), the slot groups 111 can adopt an asymmetrical design. For example, two slots 111 located on the two sides of the circuit board 110 within the same slot group 111 can be staggered at a predetermined distance in the second direction, rather than being opposite each other on a straight line. This ensures that the effective width of the main body of the circuit board 110 is maximized, maintaining the overall longitudinal rigidity of the circuit board 110.

[0059] Furthermore, the slot 111 on the circuit board 110 does not need to be provided between each group of adjacent latching terminals 130; instead, a slot 111 can be provided after a series of latching terminals 130 in the second direction. For example, refer to... Figure 6 A slot 111 is provided at the middle position of the second direction near the circuit board 110, which spans three latching terminals 130.

[0060] In addition, to achieve drive control of the onboard relay 120, the circuit board 110 is also provided with several device groups 140 (including surface mount components such as driver chips, resistors, and capacitors). Each device group 140 corresponds one-to-one with the onboard relay 120, and the two are arranged side by side along the third direction. Specifically, two latching terminals 130 in the same latching terminal group 130 are located on the outer sides of the assembly of the onboard relay 120 and the device group 140, respectively. This layout not only uses the larger onboard relay 120 as a structural skeleton to enhance the strength of the circuit board 110 in the third direction, but also leaves gaps between the onboard relays 120 that generate a lot of heat, forming a through airflow in the second direction, which is beneficial for heat dissipation in conjunction with an external fan. To further optimize heat dissipation, the pin terminals connecting the onboard relay 120 to the circuit board 110, namely the relay connection terminals 121, are designed to be closer to the edge of the circuit board 110 than the device group 140, thus being closer to the windward side of the air-cooled heat dissipation airflow and improving heat exchange efficiency. The location of the terminals connecting the onboard relay 120 to the circuit board 110 can be referred to Figure 8 As shown.

[0061] Next, the structure of the bus assembly 200 will be described. The bus assembly 200 is used to realize the electrical interconnection between the aforementioned distribution components 100 and between the various onboard relays 120 within the distribution components 100, forming a structure as follows: Figure 9 The flexible distribution matrix topology is shown. The bus component 200 mainly includes several first busbars 210 and several second busbars 220, which are orthogonally distributed in space. Together with the onboard relays 120 arranged in an array, they constitute the power distribution structure of the power distribution unit.

[0062] The first busbar 210 extends along a first direction (i.e., the vertical direction). Physically, each first busbar 210 spans multiple distribution components 100 arranged sequentially along the first direction. (Refer to...) Figure 9 In the circuit topology shown, the first bus 210 corresponds to the line marked in blue. Figure 9 (Only part of the circuit is marked in the image) connects the charging buses corresponding to different charging modules. One end of the first bus 210 is connected to the aforementioned charging module via a wiring component to introduce DC power output from the charging module. On the extended path, the first bus 210 is connected to the latching terminal 130 (i.e., the latching terminal 130 located on the side of the onboard relay 120) corresponding to the positions in different distribution components 100, thereby transmitting the power of the same charging module to different levels of distribution components 100.

[0063] The second busbar 220 extends along the second direction (i.e., the left-right direction). Physically, the second busbar 220 is primarily arranged within the extension range of the single distribution component 100. (Refer to...) Figure 9 The circuit topology shown here, these second buses 220 are equivalent to the lines marked in red ( Figure 9 (Only a portion of the wiring is shown in the diagram), which refers to the horizontal connections between adjacent switches. Each second bus 220 is connected to a specific terminal to collect electrical energy switched by the onboard relay 120 and output it to the load.

[0064] Furthermore, this embodiment also employs a double-sided wiring structure. Specifically, the two sides of the distribution component 100 along a third direction (i.e., the front-to-back direction) are defined as the first side and the second side, respectively. The first bus 210 and the second bus 220 are located on opposite sides of the distribution component 100 along the third direction, respectively. For example, referring to... Figure 3 and Figure 4 All vertically extending first buses 210 are arranged on the first side (e.g., the front side) of the circuit board 110 along a third direction, while all horizontally extending second buses 220 are arranged on the second side (e.g., the rear side) of the circuit board 110 along a third direction. In this layout, the current conduction path is clear: current from the charging module first enters the first bus 210 located on the first side; subsequently, the current reaches the corresponding latching terminal 130 on the second side of the circuit board 110 through a corresponding connector 230, and then connects to a corresponding onboard relay 120 through the second bus 220; if the control system closes the onboard relay 120, the current flows through the internal contacts of the relay to another latching terminal 130 located on the first side of the circuit board 110, and then through the latching terminal 130 to the corresponding other first bus 210, and then through the first bus 210 to the load. This design makes... Figure 9 Each switch in the topology physically corresponds to a specific onboard relay 120. By controlling the on / off state of the onboard relay 120, the connection or disconnection between any vertical line and any horizontal line can be achieved.

[0065] In addition, the busbar assembly 200 also includes several connection bars 230, which are also copper busbars. They cross the first and second sides of the distribution assembly 100 in a third direction to connect the latching terminals 130 corresponding to the different onboard relays 120 located on both sides. The first busbar 210 and the second busbar 220 on the first and second sides are connected through the connection bars 230 to form a complete matrix switching circuit.

[0066] The power distribution unit provided in this embodiment includes a positive line and a negative line, therefore its actual number of switches is: Figure 9 Twice the topology shown.

[0067] Next, the structure of the outer frame 300 will be explained.

[0068] Reference Figure 1 and Figure 2 The outer frame 300 includes two side frames 310 spaced apart along a second direction, and a top frame 320 and a bottom frame 330 connecting the top and bottom of the side frames 310. The side frames 310 extend along a first direction and have a plurality of grooves 311 arranged along the first direction on their inner surfaces. The grooves 311 extend along a third direction, and their openings (e.g., openings facing the first side), i.e., groove openings 312, are flared outwards in a trumpet shape. During installation, the two ends of the circuit board 110 in the dispensing assembly 100 are inserted into the corresponding grooves 311 along the third direction. The trumpet-shaped groove openings 312 serve as guides, facilitating the quick alignment and insertion of the circuit board 110. After the dispensing assembly 100 is inserted into place, a removable limiting baffle is installed on the other side (e.g., the second side) of the side frame 310 to block the openings of the grooves 311, thereby restricting the dispensing assembly 100 from disengaging along the third direction. When maintenance is required on a particular distribution component 100, it is only necessary to remove the connecting bolts of the first busbar 210 and the second busbar 220 connected to the distribution component 100 and remove the limit baffle. The specific distribution component 100 can then be pulled out of the outer frame 300 for inspection or replacement without disassembling the entire power distribution unit, which greatly improves the convenience of maintenance.

[0069] The outer frame 300 also includes a slide rail 313, which can be fixedly installed on the inner side of the side frame 310 by bolts, and a slide groove 311 is formed on the slide rail 313.

[0070] Furthermore, given that the second bus 220 extends a long distance horizontally and needs to carry the large current after convergence, it is relatively heavy. To prevent the second bus 220 from generating excessive torque on the circuit board 110 and to prevent the circuit board 110 from deforming due to the weight, this embodiment also includes at least one reinforcing member 400. (Refer to...) Figure 1 The reinforcing member 400 extends along the first direction, with one end (e.g., the top or bottom end) securely connected to the top frame 320 and / or the bottom frame 330 of the outer frame 300, and the other end spanning several distribution components 100 and mechanically fixed to an intermediate fixing member located in the middle of the vertical direction and fixed to the two side frames 310.

[0071] Finally, the connection relationship between the wiring components and the power distribution unit in the charging equipment is explained. The wiring components are used to introduce electrical energy into the power distribution unit and to output the distributed electrical energy to the load. The wiring components connect the power distribution unit and each charging module, and are provided with terminals corresponding to each load. The wiring components mainly include a terminal block connecting each first busbar 210 in the power distribution unit. One end of this terminal block is connected to the end of a first busbar 210 of the charging module and the power distribution unit, and the other end forms a terminal block connected to a load. When charging is required, a load is connected to a terminal block, and the electrical energy of the charging module can be directly output to the load through the terminal block. At the same time, the electrical energy of other charging modules can be connected to this terminal block through the power distribution unit, thereby realizing flexible switching.

[0072] Example 2

[0073] The difference between Embodiment 2 and Embodiment 1 is that the structure of the slot 111 in the circuit board 110 of the distribution component 100 is different.

[0074] Reference Figure 7 In Embodiment 2, the circuit board 110 has a group of three slots 111. Two of these slots 111 are located on one side edge of the circuit board 110 along a third direction, forming two first slots 112. The other slot 111 is located on the other side edge, forming a second slot 113. The width of the second slot 113 is greater than that of the first slot 112. This arrangement creates a cantilever structure with a certain width along a second direction between the two first slots 112, which can accommodate uneven stress on the two sides of the circuit board 110 in the third direction, effectively improving the overall structural strength of the circuit board 110. Preferably, the distance between the two first slots 112 is set to be approximately equal to the width of the second slot 113 to ensure the symmetry of the portion of the circuit board 110 used to mount the latching terminal 130 in the third direction. Preferably, one side of the circuit board 110 with the first slot 112 is located on the first side corresponding to the first busbar 210, and one side of the circuit board 110 with the second slot 113 is located on the second side corresponding to the second busbar 220.

[0075] Example 3

[0076] The difference between Embodiment 3 and Embodiment 1 is that the structure of the slot 111 in the circuit board 110 of the distribution component 100 is different.

[0077] Reference Figure 8In Embodiment 3, the circuit board 110 has two slots 111, which are located on one side edge of the circuit board 110 along a third direction. The width of one slot 111 is greater than that of the other slot 111. The slot 111 with the narrower width can be located in the middle of its two adjacent latching terminals 130. Preferably, the side of the circuit board 110 with the narrower slot 111 is located on the first side corresponding to the first busbar 210, and the side of the circuit board 110 with the wider slot 111 is located on the second side corresponding to the second busbar 220.

[0078] In at least one embodiment, the power distribution unit includes: a plurality of distribution components 100, each distribution component 100 being arranged sequentially along a first direction; each distribution component 100 includes a circuit board 110 and a plurality of onboard relays 120; the circuit board 110 extends along a second direction, and each onboard relay 120 is disposed on the circuit board 110; the second direction is perpendicular to the first direction; a bus component 200, which includes a plurality of first busbars 210 and a plurality of second busbars 220, the first busbars 210 crossing at least one distribution component 100 and connecting one end of each onboard relay 120 located in different distribution components 100, the second busbars 220 connecting the other end of each onboard relay 120 located in the distribution component 100, so as to connect or disconnect the current circuit through the onboard relays 120; an outer frame 300, which includes at least two side frames 310 arranged along the second direction; the two ends of the circuit board 110 in the distribution component 100 along the second direction are inserted and fixed to the corresponding side frames 310 along a third direction; the third direction is perpendicular to the first direction and the second direction.

[0079] The power distribution unit is provided with several distribution components 100 arranged sequentially along a first direction. These distribution components 100 include a circuit board 110 extending along a second direction and several onboard relays 120. By replacing the high-voltage DC contactor in a conventional power distribution unit with onboard relays 120, the miniaturization advantage of the onboard relays 120 is utilized, initially reducing the size of the power distribution unit and lowering the overall manufacturing cost. At the same time, the distribution components 100 are stacked in the first direction, effectively utilizing the space of the cabinet in this direction, and making the distance between the onboard relays 120 in adjacent distribution components 100 approximately the same, facilitating the interconnection of the onboard relays 120 in different distribution components 100. Based on this, the power distribution unit is equipped with a bus assembly 200, which includes a first bus 210 and a second bus 220. These are used to connect the onboard relays 120 in different distribution components 100 and to connect the onboard relays 120 within the same distribution component 100, respectively. Combined with the structure where the onboard relays 120 are mounted on the circuit board 110, the overall bus path is clear, and the switching path is more clearly defined when constructing a flexible switching topology. Furthermore, since the onboard relays 120 are connected through this bus assembly 200, the number of onboard relays 120 in each distribution component 100 can be set to the same value. This ensures that the configuration of each distribution component 100 is identical, further improving the standardization of the design and manufacturing of the distribution components 100 and reducing the overall design and manufacturing cost. Moreover, compared to conventional power distribution units using high-voltage DC contactors, this power distribution unit is easier to maintain. Since all onboard relays 120 are mounted on the circuit board 110, and the circuit board 110 is fixed to the side frame 310 in the outer frame 300 via plug-in connection, when maintenance or replacement of the onboard relays 120 is required, the connection between the corresponding locked first busbar 210 and second busbar 220 in the bus assembly 200 and the distribution assembly 100 can be removed. The distribution assembly 100 can then be directly pulled out of the side frame 310, allowing for convenient maintenance and repair of the onboard relays 120 or the circuit board 110. Therefore, compared to conventional power distribution units using high-voltage DC contactors, this power distribution unit has advantages such as small size, low cost, and convenient maintenance.

[0080] In at least one embodiment, each onboard relay 120 in the distribution assembly 100 is disposed on the circuit board 110 along a second direction.

[0081] The onboard relays 120 are linearly arranged along the length of the circuit board 110, so that the onboard relays 120 in the distribution component 100 form a one-dimensional array in space. This arrangement matches the structural form of the circuit board 110 and allows all the onboard relays 120 to form a regular two-dimensional array distribution in the planes of the first and second directions after the distribution component 100 is stacked in the first direction. This simplifies the path planning and layout of the subsequent busbar component 200, avoids the messy distribution and detours of the busbar component 200, and enables standardized assembly and facilitates the disassembly and maintenance of the distribution component 100.

[0082] In at least one embodiment, in the bus assembly 200, at least a portion of the first bus 210 extends along a first direction to connect the onboard relay 120 corresponding to the position along the first direction across the distribution assembly 100, and at least a portion of the second bus 220 extends along a second direction to connect the onboard relay 120 disposed along the second direction within the distribution assembly 100.

[0083] By limiting the extension paths of the first busbar 210 and the second busbar 220 and utilizing the layout of the onboard relay 120, the busbars responsible for cross-component connections and the busbars responsible for intra-component connections are naturally separated in physical path, reducing spatial interference between buses at different potentials. This reduces the need for complex insulation isolation structures and makes the distribution of electrical connection points more regular, facilitating automated assembly and manual maintenance.

[0084] In at least one embodiment, in the distribution assembly 100, the board surface of the circuit board 110 is parallel to a third direction, and latching terminals 130 are provided on both sides of each onboard relay 120 along the third direction. The onboard relay 120 is used to control the on / off state of the corresponding two latching terminals 130. The first bus 210 and the second bus 220 in the bus assembly 200 are respectively connected to the latching terminals 130 on both sides of the onboard relay 120.

[0085] Latch terminals 130 are respectively provided on both sides of the onboard relay 120 on the circuit board 110, and the first and second busbars 220 are connected to the latch terminals 130 to facilitate the installation of the bus assembly 200 and avoid spatial interference between the bus assembly 200 and the circuit board 110.

[0086] In at least one embodiment, in the bus assembly 200, the first bus 210 and the second bus 220 are located on both sides of the distribution assembly 100 along a third direction; the side where the first bus 210 is located is defined as the first side of the third direction, and the side where the second bus 220 is located is defined as the second side of the third direction.

[0087] The first busbar 210 and the second busbar 220 are respectively arranged on both sides of the distribution component 100, so that one side of the distribution component 100 has only the first busbar 210 and the other side has only the second busbar 220. When maintenance and repair of a certain distribution component 100 is required, the distribution component 100 can be pulled out from the side with the horizontal second busbar 220, without worrying about being affected by the vertical first busbar 210, thus greatly facilitating the maintenance and repair of the distribution component 100.

[0088] In at least one embodiment, the side frame 310 is provided with a groove 311 corresponding to each circuit board 110 and extending along a third direction. The circuit board 110 is at least adapted to be inserted into the groove 311 toward a first side along a third direction and fixed in the first direction. The outer frame 300 also includes a limiting baffle, which is detachably fixed to a second side of the side frame 310 along a third direction and adapted to block the opening of the groove 311 on the second side along a third direction.

[0089] A slide groove 311 and a detachable limiting baffle are provided on the side frame 310. The slide groove 311 can be used to fix the dispensing component 100, and the limiting baffle can prevent the dispensing component 100 from coming out of the slide groove 311. When maintenance is required, the dispensing component 100 can be taken out of the slide groove 311 simply by removing the limiting baffle, without disassembling the entire outer frame 300, which facilitates the maintenance and repair of the dispensing component 100.

[0090] In at least one embodiment, the opening of the groove 311 on the second side along a third direction is in the shape of an outwardly flared trumpet.

[0091] The slide opening 312 is set in the shape of a horn so that the circuit board 110 can be guided through the opening of the slide 311 during the insertion process of the slide 311, which facilitates the insertion of the circuit board 110 into the slide 311 and can prevent the circuit board 110 from colliding with the outer frame 300, thus protecting the circuit board 110.

[0092] In at least one embodiment, the outer frame 300 further includes a top frame 320 and a bottom frame 330; the top frame 320 and the bottom frame 330 extend along a second direction and respectively connect the top and bottom of the two side frames 310.

[0093] The top frame 320 and bottom frame 330 are set to connect the two side frames 310, so that the outer frame 300 forms a closed rectangular frame structure, which significantly improves the structural stability and strength of the overall outer frame 300 and ensures that the outer frame 300 will not deform when bearing the distribution component 100 and the bus component 200.

[0094] In at least one embodiment, it further includes at least one reinforcing member 400; the reinforcing member 400 extends along a first direction, with one end fixed to the top frame 320 and / or the bottom frame 330, and the other end spanning a plurality of distribution components 100 and fixed to the second busbar 220.

[0095] The reinforcement 400 is provided to avoid the problem of insufficient rigidity of the long-span circuit board 110 or bus, and to prevent large deformation of the circuit board 110 or bus in the middle position, thereby ensuring that the circuit board 110 will not be torn by stress and improving the reliability of the power distribution unit.

[0096] In at least one embodiment, the charging device is used to charge multiple loads, including the power distribution unit as described above; and a plurality of charging modules adapted to connect to a power supply and provide matching electrical energy to the loads; and wiring components that connect the power distribution unit and each charging module, and are provided with terminals corresponding to each load; each first busbar 210 in the power distribution unit is connected to the charging module through the wiring components to distribute the electrical energy provided by the charging module to the load to at least one terminal by switching on and off each onboard relay 120 in the distribution assembly 100.

[0097] The charging device utilizes this power distribution unit, which greatly improves the utilization of its internal space, reduces the overall manufacturing cost, and lowers the maintenance cost of the power distribution unit.

[0098] The foregoing description of the specifications and embodiments is intended to explain the scope of protection of this invention, but does not constitute a limitation on the scope of protection of this invention. Modifications, equivalent substitutions, or other improvements to the embodiments of this invention or a portion thereof that can be obtained by those skilled in the art through logical analysis, reasoning, or limited experimentation, based on the teachings of this invention or the foregoing embodiments, in conjunction with common knowledge, general technical knowledge, and / or existing technology, should all be included within the scope of protection of this invention.

Claims

1. A power distribution unit, characterized in that it comprises: A plurality of distribution components (100) are arranged sequentially along a first direction; each distribution component (100) includes a circuit board (110) and a plurality of onboard relays (120); the circuit board (110) extends along a second direction, and each onboard relay (120) is disposed on the circuit board (110) along the second direction; the second direction is perpendicular to the first direction; A bus assembly (200) includes a plurality of first buses (210) and a plurality of second buses (220), wherein the first buses (210) extend along a first direction to connect one end of an onboard relay (120) located along the first direction across the distribution assembly, and the second buses (220) extend along a second direction to connect the other end of an onboard relay (120) disposed along the second direction within the distribution assembly (100) to connect or disconnect a current loop through the onboard relay (120); the first buses (210) and the second buses (220) are respectively located on both sides of the distribution assembly (100) along a third direction; The outer frame (300) includes at least two side frames (310) arranged along the second direction; the two ends of the circuit board (110) in the distribution assembly (100) along the second direction are inserted and fixed to the corresponding side frames (310) along a third direction; the third direction is perpendicular to the first direction and the second direction.

2. A power distribution unit as claimed in claim 1, characterized in that In the distribution assembly (100), the board surface of the circuit board (110) is parallel to the third direction, and latching terminals (130) are provided on both sides of each onboard relay (120) along the third direction. The onboard relay (120) is used to control the on / off state of the corresponding two latching terminals (130). The first bus (210) and the second bus (220) in the bus assembly (200) are respectively connected to the latching terminals (130) on both sides of the onboard relay (120).

3. A power distribution unit as claimed in claim 2, characterized in that the definition The side where the first busbar (210) is located is the first side in the third direction, and the side where the second busbar (220) is located is the second side in the third direction; the side frame (310) is provided with a groove (311) corresponding to each of the circuit boards (110) and extending in the third direction, the circuit board (110) is at least adapted to be inserted into the groove (311) in the third direction toward the first side and fixed in the first direction; the outer frame (300) also includes a limiting baffle, the limiting baffle is detachably fixed to the second side of the side frame (310) in the third direction, and is adapted to block the opening of the groove (311) in the second side in the third direction.

4. A power distribution unit as claimed in claim 3, characterized in that The opening of the groove (311) on the second side along the third direction is in the shape of an outwardly flared trumpet.

5. A power distribution unit as claimed in claim 1, characterized in that The outer frame (300) also includes a top frame (320) and a bottom frame (330); the top frame (320) and the bottom frame (330) extend along a second direction and respectively connect the top and bottom of the two side frames (310).

6. A power distribution unit as claimed in claim 5, characterized in that It also includes at least one reinforcing member (400); the reinforcing member (400) extends along a first direction, with one end fixed to the top frame (320) and / or the bottom frame (330), and the other end spanning a plurality of the distribution components (100) and fixed to the second busbar (220).

7. A charging device for charging a plurality of loads, characterized by, Includes the power distribution unit as described in any one of claims 1-6; and Several charging modules, adapted to connect to a power supply and provide matching electrical energy to the load; and A wiring component, which connects the power distribution unit and each of the charging modules, and is provided with wiring terminals corresponding to each of the loads; Each of the first busbars (210) in the power distribution unit is connected to the charging module through the wiring component, so as to distribute the power supplied by the charging module to the load to at least one of the wiring terminals by switching on and off the onboard relays (120) in the distribution assembly (100).

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