A BDU structure

Abstract

This invention relates to the field of battery pack power distribution safety technology, and in particular to a BDU structure, including a fuse module, a precharge module, and a relay module. Connecting components are mirror-imagely staggered on both sides of the fuse module, precharge module, and relay module. Heat dissipation components are located on the underside of the fuse module, precharge module, and relay module. The connecting components include connecting plates, which are mirror-imagely staggered on both sides of the fuse module, precharge module, and relay module. This invention disassembles the BDU into independent fuse modules, precharge modules, and relay modules. These modules are quickly assembled and installed through connecting components, allowing for flexible adjustment of the module order according to the battery pack interface position. This eliminates the need for re-molding and repeated testing, shortening the development cycle and reducing costs associated with mold investment, production line equipment investment, and inventory management. Furthermore, the modular design allows for individual replacement of damaged modules, facilitating maintenance.

Description

Technical Field

[0001] This invention relates to the field of battery pack power distribution safety technology, and in particular to a BDU structure. Background Technology

[0002] In new energy vehicle battery packs, the Battery Energy Distribution Unit (BDU) is a core component for high-voltage power distribution and safety protection, responsible for controlling the on / off switching of high-voltage current and providing overcurrent and short-circuit protection. Currently, BDUs on the market are all non-standard customized parts. When different vehicle models, battery pack interface positions, and electrical parameters change, it is necessary to redesign the integrated BDU housing, internal bus layout, and installation structure.

[0003] This non-standard customization model necessitates the creation of new molds and the re-testing of vibration, thermal cycling, and overload tests for each BDU, wasting testing resources and development time. Furthermore, the highly integrated components of the integrated BDU, such as relays, fuses, and pre-charge resistors, mean that if any component fails or the battery pack interface position is adjusted, the entire BDU assembly often needs to be replaced, resulting in high maintenance costs and poor flexibility. In addition, existing BDU heat dissipation structures are mostly integrated with the housing, leading to poor heat dissipation due to housing limitations. Therefore, we propose a new BDU structure. Summary of the Invention

[0004] In order to overcome the technical problems existing in the prior art, the present invention provides a BDU structure.

[0005] To solve the above technical problems, the present invention provides the following technical solution: including a fuse module, a precharge module and a relay module, wherein the fuse module, the precharge module and the relay module are provided with connecting components on both sides in a mirror-like alternating manner, and heat dissipation components are provided on the lower side of the fuse module, the precharge module and the relay module; The connecting assembly includes a connecting plate, which is mirror-interleaved on both sides of the fuse module, precharge module, and relay module. A guide post, a connecting block, and a hook block are fixedly provided on the side of the connecting plate. A guide groove is provided on the side of the connecting plate. The guide post slides into the guide groove, and the hook block slides into the connecting block. A limit rod is provided on the side of the connecting block. The limit rod limits the connecting plate. When the limit rod is pulled away from the guide post, it unlocks the connecting plate. The heat dissipation assembly includes a heat dissipation plate with equidistant flow channels on its side. A positioning block is provided on the upper side of the heat dissipation plate. The connecting plate has flow channels, openings, and slots inside and on its side. Cooling water is guided to carry away the heat from the connecting plate and cools the fuse module, precharge module, and relay module. A locking block is provided on the side of the connecting plate to limit the position of the assembled connecting plate.

[0006] Furthermore, a circuit board is provided above the fuse module, precharge module, and relay module, and a connector is fixedly provided on the upper side of the circuit board. Copper busbar modules are provided on the sides of the fuse module, precharge module, and relay module. A positive copper busbar terminal is fixedly provided on the side of the fuse module, and a negative copper busbar terminal is fixedly provided on the side of the relay module. A protective shell is provided to cover the sides of the fuse module, precharge module, and relay module.

[0007] Furthermore, the connecting plate is fixedly installed on both sides of the fuse module, precharge module and relay module. The connecting plate is an "L" shaped plate made of heat-conducting material. The guide groove corresponds to the position of another set of guide posts. The positions of the connecting blocks and hook blocks on the sides of the two sets of connecting plates are staggered and correspond to each other.

[0008] Furthermore, the connecting block has an inner cavity, a movable rod is movably installed inside the cavity, and part of the movable rod extends out of the cavity. A support cylinder is fixedly connected between the side of the movable rod and the wall of the cavity, and the support cylinder is movably sleeved on the side of the movable rod.

[0009] Furthermore, the top wall of the active cavity is provided with a mating cavity, which extends through the connecting block. A deformable part is movably arranged inside the mating cavity, and one side of the deformable part is fixedly connected to the wall of the mating cavity. A limiting rod is fixedly installed on the other side of the deformable part and extends out of the mating cavity to the guide post.

[0010] Furthermore, the heat sink is located on the lower side of the fuse module, precharge module and relay module, and the flow channel is connected to the water cooling circulation path of the battery pack through a pipe. A threaded hole is opened on the side of the heat sink corresponding to the position of the flow channel, and the positioning block is threadedly installed in the threaded hole.

[0011] Furthermore, the flow guiding cavity is opened inside the connecting plate, the openings are symmetrically opened on the bottom wall of the flow guiding cavity, the positioning blocks are inserted into the openings accordingly, the slots are opened on the lower side of the guide post and the positioning blocks are inserted into the slots accordingly, the wall of the flow guiding cavity is provided with mating holes that penetrate the heat dissipation plate at equal intervals corresponding to the guide slots, and the wall of the slots is provided with mating slots that penetrate the heat dissipation plate at equal intervals corresponding to the mating holes.

[0012] Furthermore, the locking block is slidably installed inside the mating groove and is attached to the wall of the mating groove. A tension spring is fixedly connected between the side of the locking block and the wall of the mating groove.

[0013] Compared with the prior art, the beneficial effects that this invention can achieve are: 1. This invention splits the BDU into independent fuse modules, precharge modules, and relay modules. The modules are connected by connecting components to achieve rapid assembly and installation. This allows for flexible adjustment of the module order according to the battery pack interface position, eliminating the need for re-molding and repeated testing and verification. This shortens the development cycle and reduces costs associated with mold investment, production line equipment investment, and inventory management. At the same time, the modular design allows for individual replacement of damaged modules, making maintenance convenient.

[0014] 2. This invention achieves rapid guiding assembly and error prevention between modules by setting up connecting components, including the mating structure of guide posts and guide grooves, the limiting structure of connecting blocks and hook blocks, and the positioning detection mechanism composed of movable rods, deformable parts and limiting rods. When the modules are not assembled in place, the limiting rod will cause interference, and the installers can quickly identify the abnormality, thereby improving the reliability and efficiency of assembly.

[0015] 3. This invention, by setting up a heat dissipation component, including a heat dissipation plate, a flow guide groove, a positioning block, a flow guide cavity, and a floating limiting structure composed of a locking block and a tension spring, achieves precise positioning and installation of the module while using the existing water cooling circulation path of the battery pack to assist in heat dissipation of the connecting plate. Furthermore, when the cooling water flows, it pushes the locking block part into the mating hole, further applying limiting constraints to the assembled connecting plate, thereby improving the heat dissipation effect and mechanically strengthening the locking function.

[0016] 4. The present invention uses the mirrored and staggered connection components on both sides of each module to enable any two adjacent modules to be connected through the same connection structure, which has good interchangeability between modules and improves the field adaptability of BDU. Attached Figure Description

[0017] Figure 1 This is a partial structural schematic diagram of the present invention; Figure 2 This is a schematic diagram of the overall structure of the present invention; Figure 3 This is a schematic diagram showing the assembly of the various components of the present invention; Figure 4 This is a schematic diagram of the peripheral structure of the fuse module of the present invention; Figure 5 This is a schematic diagram of the structure of the connecting component of the present invention; Figure 6 This is a cross-sectional structural diagram of the connecting component of the present invention; Figure 7 This is a partial structural schematic diagram of the heat dissipation component of the present invention; Figure 8 This is a partial structural cross-sectional view of the heat dissipation component of the present invention.

[0018] The components include: 1. Fuse module; 11. Protective shell; 2. Precharge module; 3. Relay module; 4. Circuit board; 41. Connector; 5. Copper busbar module; 51. Positive copper busbar end; 52. Negative copper busbar end; 6. Connecting assembly; 61. Connecting plate; 62. Guide post; 621. Guide groove; 63. Connecting block; 64. Hook block; 65. Movable cavity; 651. Movable rod; 652. Support cylinder; 66. Mating cavity; 661. Deformable part; 67. Limiting rod; 7. Heat dissipation assembly; 71. Heat dissipation plate; 711. Flow guide groove; 712. Positioning block; 72. Flow guide cavity; 721. Opening; 73. Slot; 74. Mating hole; 75. Mating groove; 76. Locking block; 77. Tension spring. Detailed Implementation

[0019] To make the technical means, creative features, and achieved objectives and effects of this invention easier to understand, the invention is further described below with reference to specific embodiments. However, the following embodiments are merely preferred embodiments of this invention and not all of them. Other embodiments obtained by those skilled in the art based on the embodiments described herein without creative effort are all within the protection scope of this invention. Unless otherwise specified, the experimental methods in the following embodiments are conventional methods, and the materials and reagents used in the following embodiments are commercially available unless otherwise specified.

[0020] Example: Figure 1 and Figure 2As shown, a BDU structure includes a fuse module 1, a precharge module 2, and a relay module 3. The number of modules can be selected according to requirements, and the positions of these different modules can be adjusted to achieve various combinations. Different combinations can adapt to different interface positions of the battery pack. In this embodiment, the fuse module 1 and precharge module 2 are in one group, and the relay module 3 is in two groups. The relay module 3 is alternately arranged with the fuse module 1 and precharge module 2. A circuit board 4 is arranged above the fuse module 1, precharge module 2, and relay module 3, and is fixed with screws. A connector 41 is fixedly arranged on the upper side of the circuit board 4. The circuit board 4 performs voltage acquisition, relay voltage acquisition, relay coil control, and low-voltage signal acquisition and output from the precharge line and shunt to the connector 41 for the fuse module 1, precharge module 2, and relay module 3. A copper busbar module 5 is arranged on the side of the fuse module 1, precharge module 2, and relay module 3, and the copper busbar module 5 connects the conductors on the side of the fuse module 1, precharge module 2, and relay module 3. A positive copper busbar 51 is fixedly installed on the side of the fuse module 1, and the positive copper busbar 51 is connected to the positive terminal of the battery pack. A negative copper busbar 52 is fixedly installed on the side of the relay module 3, and the negative copper busbar 52 is connected to the negative terminal of the battery pack. Connecting components 6 are arranged in a mirror-like staggered manner on both sides of the fuse module 1, precharge module 2, and relay module 3. The connecting components 6 can realize the quick combination and installation between the fuse module 1, precharge module 2, and relay module 3, making the fuse module 1, precharge module 2, and relay module 3 into detachable and flexible modules that can be used for non-standard quick combination tests. A heat dissipation component 7 is provided on the lower side of the fuse module 1, precharge module 2, and relay module 3. The heat dissipation component 7 can position the fuse module 1, precharge module 2, and relay module 3 after they are combined, and connect to the water path of the battery pack to provide auxiliary heat dissipation for each module during use. A protective shell 11 is provided on the side of the fuse module 1, precharge module 2, and relay module 3 for protection and insulation.

[0021] like Figures 3 to 6As shown, the connecting assembly 6 includes a connecting plate 61, which is fixedly installed on both sides of the fuse module 1, the precharge module 2, and the relay module 3. Two sets of connecting plates 61 are mirror-image staggered on both sides of the fuse module 1, the precharge module 2, and the relay module 3. The connecting plate 61 is an L-shaped plate made of thermally conductive material. Guide posts 62, which are trapezoidal blocks made of thermally conductive material, are fixedly installed on the side of the connecting plate 61. A guide groove 621 is formed on the side of the connecting plate 61, corresponding to the position of the other set of guide posts 62. The guide groove 621 is a trapezoidal groove. Connecting... Block 63 and hook block 64 are connected to each other on the sides of the two sets of connecting plates 61. The connecting block 63 is a "C" shaped block and the hook block 64 is a trapezoidal block. Specifically, the fuse module 1, the precharge module 2 and the relay module 3 are guided by the guide post 62 on the corresponding side to slide into the corresponding guide groove 621, so as to realize the quick connection between the corresponding connecting plates 61. This completes the quick connection and installation between the fuse module 1, the precharge module 2 and the relay module 3. At the same time, the corresponding hook block 64 slides into the position of the connecting block 63, and the connecting block 63 limits the hook block 64. The connecting block 63 has an inner cavity 65, which is a cylindrical cavity with a convex cross-section. A movable rod 651 is movably installed inside the cavity 65, with a portion of the rod extending out of the cavity. The movable rod 651 is a T-shaped cylindrical rod. A support cylinder 652 is fixedly connected between the side of the movable rod 651 and the wall of the cavity 65, and is movably sleeved on the side of the movable rod 651. The support cylinder 652 is an elastic bellows. A mating cavity 66 is formed on the top wall of the cavity 65, extending through the connecting block 63. The mating cavity 66 is an L-shaped groove. A deformable part 661 is movably installed inside the mating cavity 66, with one side fixedly connected to the wall of the cavity 66. The deformable part 661 is made of a resiliently restorable material, such as a nickel-titanium shape memory alloy. A limit rod 67 is fixedly installed on the other side of the deformable part 661. The limiting rod 67 extends from the mating cavity 66 to the guide post 62. Specifically, when the hook block 64 slides into the inner side of the connecting block 63, the hook block 64 presses against the movable rod 651. The lower end of the movable rod 651 is pressed into the movable cavity 65, and the upper end of the movable rod 651 is pushed into the mating cavity 66. The movable rod 651 compresses the deformable part 661, causing it to deform. The deformed part 661 pulls the limiting rod 67, which slides under the constraint of the connecting block 63. The limiting rod 67 moves away from the guide post 62. At this time, the guide post 62 slides into the guide groove 621 of the corresponding connecting plate 61 without interference. When the hook block 64 and the connecting block 63 do not mate properly, the limiting rod 67 can play a limiting role when the guide post 62 slides into the guide groove 621. When the assembly of the connecting plate 61 is interfered with, the abnormal assembly state can be quickly determined and the problem can be detected and investigated.

[0022] like Figures 3 to 8As shown, the heat dissipation assembly 7 includes a heat sink 71, which is located below the fuse module 1, the precharge module 2, and the relay module 3. Equivalently spaced flow channels 711 are formed on the side of the heat sink 71, which can be connected to the battery pack's water-cooling circulation path via pipes. A positioning block 712, a hollow circular block, is provided on the upper side of the heat sink 71. Threaded holes are formed on the side of the heat sink 71 corresponding to the flow channels 711, and the positioning block 712 is threaded into these holes. A flow channel 72 is formed inside the connecting plate 61, and symmetrical through-connectors are formed on the bottom wall of the flow channel 72 corresponding to both sides of the guide groove 621. The plate 61 has an opening 721, and the positioning block 712 is inserted into the opening 721. A slot 73 is provided on the lower side of the guide post 62, and the positioning block 712 is inserted into the slot 73. The slot 73 is a cylindrical cavity. On the wall of the flow guiding cavity 72, corresponding to the guide slot 621, there are equidistant mating holes 74 penetrating the heat dissipation plate 71. The mating holes 74 are circular holes. On the wall of the slot 73, corresponding to the mating holes 74, there are equidistant mating grooves 75 penetrating the heat dissipation plate 71. The mating grooves 75 are cylindrical grooves with a convex cross-section. A locking block 76 is slidably installed inside the mating groove 75 and fits against the wall of the mating groove 75. The locking block 76 is a circular ring block. A tension spring 77 is fixedly connected between the side surface of the 6th panel and the wall of the mating groove 75. Specifically, the positions of the fuse module 1, precharge module 2, and relay module 3 are selected according to their combination. After the positions are selected, threaded holes are made on the corresponding side surface of the heat sink 71, and positioning blocks 712 are installed and fixed inside the threaded holes. When installing the fuse module 1, precharge module 2, and relay module 3, the positioning blocks 712 can be inserted into the openings 721 and slots 73 on the side surface of the corresponding connecting plate 61 to position the fuse module 1, precharge module 2, and relay module 3. After the connecting plates 61 on the sides of the fuse module 1, precharge module 2, and relay module 3 are aligned and installed in place, The positions of the mating groove 75 and the mating hole 74 are made to correspond perfectly. The internal water cooling circulation path of the battery pack is connected to the corresponding guide groove 711 through the pipe. After the fuse module 1, precharge module 2 and relay module 3 are combined, they are tested. At this time, the cooling water is guided into the slot 73 through the guide groove 711, flows into the mating hole 74 through the mating groove 75 and into the guide cavity 72, and finally flows out into the corresponding guide groove 711 through the opening 721, completing the cooling water circulation. When the cooling water flows, it pushes the locking block 76. The locking block 76 partially slides into the mating hole 74, pulling the tension spring 77 to deform, further limiting and constraining the combined connecting plate 61.

[0023] Working principle: The first step is to determine the position of the non-standard combination. After the interface position of the battery pack is changed on site, the combination order is recombined according to the interface position. After determining the combination position of fuse module 1, precharge module 2 and relay module 3, threaded holes are opened at the corresponding positions on the side of heat sink 71, and positioning block 712 is installed and fixed inside the threaded holes. Then, the simulated circulating water path is connected to the corresponding guide channel 711 through the pipe. The second step is the positioning and assembly installation. The fuse module 1, precharge module 2, and relay module 3 are installed and fixed in sequence. The positioning block 712 can then be inserted into the opening 721 and slot 73 on the side of the corresponding connecting plate 61. The guide post 62 slides into the corresponding guide groove 621 to guide the assembly position. At the same time, the hook block 64 slides to the position limit of the connecting block 63. The movable rod 651 is squeezed by the hook block 64 to push the deformable part 661 to deform, so that the deformable part 661 pulls the limit rod 67 away from the guide post 62. When the hook block 64 matches the position of the connecting block 63, the connecting plate 61 is not limited by the limit rod 67. When the hook block 64 does not match the position of the connecting block 63, the limit rod 67 limits the connecting plate 61, so that the guide post 62 cannot slide completely into the guide groove 621, which makes it convenient for installers to quickly identify abnormalities. The third step involves simulation testing. After the fuse module 1, precharge module 2, and relay module 3 are assembled and installed, they are connected to the circuit via the copper busbar module 5. The circuit is then connected to the simulated battery pack circuit via the positive copper busbar terminal 51 and the negative copper busbar terminal 52 to perform a simulated battery pack usage verification operation. Cooling water flows through the guide groove 711 into the slot 73, and then through the mating groove 75 and the mating hole 74 into the guide cavity 72. After the cooling water carries away the heat from the connecting plate 61, it is discharged from the opening 721 to the corresponding guide groove 711 to complete the circulation. The synchronous block 76 is pushed by the cooling water and partially slides into the mating hole 74 to further limit and constrain the connection plate 61 at the corresponding position.

[0024] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited thereto. Various changes can be made within the scope of knowledge possessed by those skilled in the art without departing from the spirit of the present invention.

Claims

1. A BDU structure, including a fuse module (1), a precharge module (2) and a relay module (3), with connecting components (6) arranged in a mirror-like alternating manner on both sides of the fuse module (1), the precharge module (2) and the relay module (3), and a heat dissipation component (7) arranged on the lower side of the fuse module (1), the precharge module (2) and the relay module (3). Its features are: The connecting assembly (6) includes a connecting plate (61), which is mirror-interleaved on both sides of the fuse module (1), the precharge module (2) and the relay module (3). The side of the connecting plate (61) is fixedly provided with a guide post (62), a connecting block (63) and a hook block (64). The side of the connecting plate (61) is provided with a guide groove (621). The guide post (62) slides into the guide groove (621), and the hook block (64) slides into the connecting block (63). The side of the connecting block (63) is provided with a limit rod (67). The limit rod (67) limits the connecting plate (61). When the limit rod (67) is pulled away from the guide post (62), it unlocks the connection plate (61). The heat dissipation assembly (7) includes a heat dissipation plate (71), and the heat dissipation plate (71) has equidistant flow channels (711) on its side. A positioning block (712) is provided on the upper side of the heat dissipation plate (71). The connecting plate (61) has a flow channel (72), an opening (721) and a slot (73) inside and on its side. Cooling water is guided to carry away the heat of the connecting plate (61) and cools down the fuse module (1), the precharge module (2) and the relay module (3). A locking block (76) is provided on the side of the connecting plate (61) and the locking block (76) limits the combined connecting plate (61).

2. The BDU structure according to claim 1, characterized in that: A circuit board (4) is provided above the fuse module (1), the precharge module (2) and the relay module (3). A connector (41) is fixedly provided on the upper side of the circuit board (4). A copper busbar module (5) is provided on the side of the fuse module (1), the precharge module (2) and the relay module (3). A positive copper busbar terminal (51) is fixedly provided on the side of the fuse module (1), and a negative copper busbar terminal (52) is fixedly provided on the side of the relay module (3). A protective shell (11) is provided covering the side of the fuse module (1), the precharge module (2) and the relay module (3).

3. A BDU structure according to claim 2, characterized in that: The connecting plate (61) is fixedly installed on both sides of the fuse module (1), the precharge module (2) and the relay module (3). The connecting plate (61) is an "L" shaped plate made of heat-conducting material. The guide groove (621) corresponds to the position of another set of guide posts (62). The positions of the connecting blocks (63) and hook blocks (64) on the sides of the two sets of connecting plates (61) are staggered and correspond to each other.

4. A BDU structure according to claim 3, characterized in that: The connecting block (63) has an inner cavity (65). A movable rod (651) is movably installed inside the movable cavity (65), and part of the movable rod (651) extends out of the movable cavity (65). A support cylinder (652) is fixedly connected between the side of the movable rod (651) and the wall of the movable cavity (65), and the support cylinder (652) is movably sleeved on the side of the movable rod (651).

5. A BDU structure according to claim 4, characterized in that: The top wall of the active cavity (65) is provided with a mating cavity (66), and the mating cavity (66) extends through the connecting block (63). A deformable part (661) is movably arranged inside the mating cavity (66), and one side of the deformable part (661) is fixedly connected to the wall of the mating cavity (66). A limiting rod (67) is fixedly installed on the other side of the deformable part (661), and the limiting rod (67) extends out of the mating cavity (66) to the guide post (62).

6. A BDU structure according to claim 5, characterized in that: The heat sink (71) is located on the lower side of the fuse module (1), the precharge module (2) and the relay module (3). The guide groove (711) is connected to the water cooling circulation path of the battery pack through a pipe. The side of the heat sink (71) has a threaded hole corresponding to the position of the guide groove (711), and the positioning block (712) is threaded into the threaded hole.

7. A BDU structure according to claim 6, characterized in that: The flow guiding cavity (72) is opened inside the connecting plate (61). The opening (721) is symmetrically opened on the bottom wall of the flow guiding cavity (72). The positioning block (712) is inserted into the opening (721). The slot (73) is opened on the lower side of the guide post (62) and the positioning block (712) is inserted into the slot (73). The wall of the flow guiding cavity (72) is provided with mating holes (74) that penetrate the heat sink (71) at equal intervals corresponding to the guide slot (621). The wall of the slot (73) is provided with mating slots (75) that penetrate the heat sink (71) at equal intervals corresponding to the mating holes (74).

8. A BDU structure according to claim 7, characterized in that: The locking block (76) is slidably installed inside the mating groove (75) and the locking block (76) is attached to the wall of the mating groove (75). A tension spring (77) is fixedly connected between the side of the locking block (76) and the wall of the mating groove (75).

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