Integrated BDU structure design

Abstract

The invention relates to the field of new energy automobile power battery systems, in particular to an integrated BDU structural design which comprises an upper shell and a lower shell, the upper shell and the lower shell are detachably connected and clamped, the lower shell is defined by a bottom wall and a side wall, a containing cavity with an opening in the upper end is formed, and the upper end of the containing cavity is provided with an opening in the lower end. A plurality of components are arranged in the accommodating cavity and are connected through copper bars, so that the problems of low space utilization rate, independent arrangement of a plurality of components, complicated assembly, more wire harnesses, redundant internal space, long signal transmission path, increased electromagnetic interference risk, high reliability and the like of a separate framework of the BDU at the present stage are solved. And meanwhile, the assembly time and the cost are also increased.

Description

Technical Field

[0001] This invention relates to the field of power battery systems for new energy vehicles, and specifically to an integrated BDU structure design. Background Technology

[0002] As the core safety and power distribution component of the power battery system of new energy vehicles, the BDU undertakes key functions such as high voltage circuit switching, energy distribution and fault protection. Its performance directly determines the safety and energy efficiency of the whole vehicle. Ordinary BDUs have problems such as large space occupation, redundant wiring harnesses, and scattered fault points. Moreover, they only support a single voltage platform and cannot adapt to the platform development needs of multiple vehicle models.

[0003] The current BDU's discrete architecture has low space utilization, multiple components are set independently, assembly is complex, there are many wiring harnesses, internal space redundancy, long signal transmission paths, and increased risk of electromagnetic interference. It also increases assembly time and cost. Moreover, with the rapid development of new energy vehicle technology, higher requirements are placed on the integration, lightweighting and multi-voltage platform compatibility of BDU. The existing BDU structure is gradually unable to adapt to the new development trend.

[0004] In summary, an integrated BDU structure design is proposed to address the problems mentioned in the background section. Summary of the Invention

[0005] The purpose of this invention is to provide an integrated BDU structure design to solve the problems mentioned in the background art.

[0006] To address the aforementioned technical issues, this invention provides an integrated BDU structure design that abandons the traditional separate architecture. It integrates core components of the BDU, such as high-voltage relays and fuses, into a single integrated housing structure, eliminating redundant separate mounting brackets and connection structures within the battery pack. Simultaneously, it simplifies wiring harness design, eliminates wiring harness redundancy, and improves space utilization. This design enables adaptation to gasoline versions with 33.83kWh and 19kWh battery capacities, meeting the needs of multi-vehicle platform development.

[0007] An integrated BDU structure design includes an upper housing and a lower housing, which are detachably connected and interlocked. The lower housing is formed by a bottom wall and side walls, creating a receiving chamber with an opening at the top. Several components are housed within the receiving chamber, and these components are connected by copper busbars.

[0008] Furthermore, the accommodating chamber of the lower housing is also provided with mounting platforms. There are three mounting platforms, all of which are integrally formed with the front sidewall of the lower housing. Each of the three mounting platforms is provided with a control element.

[0009] Further specifying, the three mounting platforms are provided with a shunt, a copper busbar, and a fuse in sequence from left to right.

[0010] Further specifying, the aforementioned components include relays and current sensors, with the relays and current sensors connected by copper busbars, the shunt and the relays connected by copper busbars, and the fuse and the relays connected by copper busbars.

[0011] Further specifying, a fuse is provided on the upper part of the mounting platform on the far right of the lower housing, and two cavities are provided on the lower part, which are separated by a partition. A pre-charge resistor and a pre-charge charger are respectively provided in the two cavities. The pre-charge relay and the pre-charge resistor are connected by a wiring harness. The pre-charge relay and the pre-charge resistor are both connected by the four relays in the wiring harness.

[0012] Furthermore, the bottom wall of the lower housing is provided with a copper busbar mounting groove, the size of which matches the size of the copper busbar, and the copper busbar can be installed in the copper busbar mounting groove and connected to the relay.

[0013] Furthermore, a socket is provided on the left side wall of the lower housing, and a wire harness plug is integrated into the socket.

[0014] Further defined, the upper housing is formed by a top wall and side walls, forming a receiving chamber with a lower opening. After the upper housing and the lower housing are engaged, the height between the receiving chamber with the lower opening and the receiving chamber with the upper opening is higher than the height of the assembled components. The upper surface of the upper housing is provided with a label and markings.

[0015] Compared with the prior art, the beneficial effects of the present invention are:

[0016] 1. The integrated architecture replaces the traditional separate design, eliminating redundant structures inside the battery pack and significantly improving space utilization.

[0017] 2. Replace wire harness connections with copper busbar connections to reduce wire harness redundancy and potential failure points, thereby improving assembly efficiency and product reliability. Attached Figure Description

[0018] Figure 1 This is a three-dimensional structural diagram of the present invention;

[0019] Figure 2 This is a three-dimensional schematic diagram of the lower housing of the present invention;

[0020] Figure 3 This is a three-dimensional diagram illustrating the assembly between the lower housing and components of the present invention. Figure 1 ;

[0021] Figure 4 This is a three-dimensional diagram illustrating the assembly between the lower housing and components of the present invention. Figure 2 .

[0022] The markings in the diagram correspond to: 1-upper housing, 2-lower housing, 21-bottom wall, 3-accommodating chamber with upper opening, 4-mounting platform, 5-first relay, 6-second relay, 7-third relay, 8-fourth relay, 9-shunt, 10-first copper busbar, 11-second copper busbar, 12-third copper busbar, 13-fuse, 14-pre-charge resistor, 15-pre-charge relay, 16-fourth copper busbar, 17-fifth copper busbar, 18-sixth copper busbar, 19-copper busbar mounting slot, 30-wire harness plug, 31-label, 32-marker. Detailed Implementation

[0023] To enable those skilled in the art to better understand the technical solution of the present invention, the technical solution of the present invention will be further described below in conjunction with the accompanying drawings and embodiments.

[0024] Example:

[0025] like Figures 1-4As shown, an integrated BDU design includes an upper housing 1 and a lower housing 2, which are detachably snapped together. The lower housing 2 is formed by a bottom wall 21 and a side wall, creating a receiving chamber 3 with an upper opening. The upper housing 1 is formed by a top wall and a side wall, creating a receiving chamber with a lower opening. When the upper housing 1 and lower housing 2 are snapped together, the receiving chamber with the lower opening and the receiving chamber with the upper opening 3 together form an installation space. Several components are installed within the installation space. The height of the installation space is higher than the height of the components to avoid situations where installation is impossible after assembly. The accommodating cavity is provided with three mounting platforms 4, all of which are integrally formed with the front side wall of the lower housing 2. The accommodating cavity of the lower housing 2 is provided with four relays: a first relay 5, a second relay 6, a third relay 7, and a fourth relay 8. The first relay 5 to the fourth relay 6 are arranged sequentially from left to right. A shunt 9 is mounted on the left mounting platform, and the shunt 9 is connected to the first relay 5 via a first copper busbar 10. The middle mounting platform is divided into two copper busbar connection ends. A second copper busbar 11 is mounted on the copper busbar connection end and is connected to the first relay 5 and the second relay 6 respectively. The third copper busbar 12 is also installed on the copper busbar connection end and is connected to the third relay 7 and the fourth relay 8 respectively. A fuse 13 is provided on the upper part of the mounting platform on the right side, and two cavities are provided on the lower part. The two cavities are separated by a partition. A pre-charge resistor 14 and a pre-charge relay 15 are respectively installed in the two cavities. The pre-charge relay 15 and the pre-charge resistor 14 are connected by a wiring harness. Both the pre-charge relay 15 and the pre-charge resistor 14 are connected to the four relays by the wiring harness. The fourth copper busbar 16 connects the fuse 13 and the fourth relay 8. It also includes a fifth copper busbar 17 and a sixth copper busbar 18. The fifth copper busbar 17 and the sixth copper busbar 18... The sixth copper busbar 18 is connected to the fast charging socket. A copper busbar mounting groove 19 is provided on the bottom wall of the lower housing 2. The fifth copper busbar 17 is installed in the copper busbar mounting groove 19. The size of the copper busbar mounting groove 19 matches the size of the fifth copper busbar 17. The fifth copper busbar 17 is connected to the second relay 6. Each copper busbar has a different shape and size, which can be better connected. A socket is provided on the left side wall of the lower housing 1. A wire harness plug 30 is integrated in the socket. Several labels and markings are provided on the upper surface of the upper housing 1. The labels include a shunt label and a traceability code label. The markings include markings for the positive and negative terminals of the battery.

[0026] When powered on, the pre-charging circuit first soft-charges the high-voltage capacitor of the entire vehicle. After the voltage is matched, the main contactor is closed to avoid large current surges. When powered off, the main contactor is directly disconnected to quickly cut off the high-voltage circuit. The shunt and acquisition module monitor the current and voltage in real time. Once overcurrent, overvoltage or other faults are detected, the contactor is immediately triggered to disconnect to ensure safety. Its modular design allows for flexible addition or removal of components and can simultaneously adapt to the 33.83kWh and 19kWh power platforms of the gasoline version, meeting the platform development needs of multiple vehicle models.

[0027] In the description of this invention, it should be understood that the terms "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are only for the convenience of describing the invention and simplifying the description, and are not intended to indicate or imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention.

[0028] The above provides a detailed description of an integrated BDU structure design provided by the present invention. The specific embodiments are only used to help understand the method and core ideas of the present invention. It should be noted that those skilled in the art can make several improvements and modifications to the present invention without departing from the present invention, and these improvements and modifications also fall within the protection scope of the claims of the present invention.

Claims

1. An integrated BDU structural design, characterized in that: It includes an upper shell (1) and a lower shell (2), which are detachably connected and engaged. The lower shell (2) is formed by a bottom wall (21) and a side wall, forming a receiving chamber (3) with an upper opening. Several components are arranged in the receiving chamber, and the components are connected to each other by copper busbars.

2. The integrated BDU structure design according to claim 1, characterized in that: The lower housing (2) is also provided with a mounting platform (4) in its accommodating chamber. There are three mounting platforms (4), and all three mounting platforms (4) are integrally formed with the front side wall of the lower housing (2). Each of the three mounting platforms (4) is provided with a control element.

3. The integrated BDU structure design according to claim 2, characterized in that: The three mounting platforms are arranged from left to right as follows: a shunt (9), a copper busbar, and a fuse (13).

4. The integrated BDU structure design according to claim 3, characterized in that: The aforementioned components include four relays, all of which are connected by copper busbars. The shunt (9) and the relays are connected by copper busbars, and the fuse (13) and the relays are connected by copper busbars.

5. The integrated BDU structure design according to claim 3, characterized in that: A fuse (13) is provided on the upper part of the mounting platform on the far right of the lower housing (2), and two cavities are provided on the lower part. The two cavities are separated by a partition. A pre-charge resistor (14) and a pre-charge relay (15) are respectively provided in the two cavities. The pre-charge relay (15) and the pre-charge resistor (14) are connected by a wire harness. The pre-charge relay (15) and the pre-charge resistor (14) are both connected to the four relays by a wire harness.

6. The integrated BDU structure design according to claim 1, characterized in that: The bottom wall of the lower housing (2) is provided with a copper busbar mounting groove (19). The size of the copper busbar mounting groove (19) matches the size of the copper busbar. The copper busbar can be installed in the copper busbar mounting groove (18) and connected to the relay.

7. The integrated BDU structure design according to claim 1, characterized in that: The lower housing (2) has an insertion hole on its left side wall, and a wire harness plug (30) is integrated into the insertion hole.

8. The integrated BDU structure design according to claim 2, characterized in that: The upper housing (1) is formed by the top wall and the side wall, forming a receiving chamber with a lower opening. After the upper housing (1) and the lower housing (2) are engaged, the height between the receiving chamber with the lower opening and the receiving chamber with the upper opening (3) is higher than the height of the several components after installation. The upper surface of the upper housing (1) is provided with a label (31) and an identifier (32).

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