High-voltage distribution box applied to vehicle-mounted charger and vehicle-mounted charger

Abstract

The utility model provides a high-voltage distribution box applied to a vehicle-mounted charger, an assembling method and the vehicle-mounted charger, and relates to the field of power supplies. Comprising a support, the support is of a two-layer support structure formed by a bottom plate, a top plate and a plurality of middle plates, and a first containing space is formed on one side of the top plate and above the bottom plate; the OBC fuse, the direct current metal bar positive end and the direct current metal bar negative end are assembled in the first accommodating space; the at least one PDU branch fuse, the plurality of positive wire harness terminals and the plurality of negative wire harness terminals are assembled on the bottom plate, the second end of the OBC fuse is sequentially connected with the first end of the at least one PDU branch fuse through the positive metal bar, and the second end of the OBC fuse is connected with the positive end of the direct current metal bar; the at least one middle positive metal bar is respectively connected with the second end of the at least one PDU branch fuse and the power positive wire harness terminal; the negative metal bar is connected with the negative end of the direct current metal bar, the power negative wire harness terminal and the high-voltage negative wire harness terminal, and the metal bar is fixed in the support in a non-detachable mode.

Description

Technical Field

[0001] The utility model relates to the field of power supplies, and in particular to a high-voltage distribution box applied to a vehicle-mounted charger, an assembly method and the vehicle-mounted charger. Background Art

[0002] In order to solve the energy crisis, the new energy vehicle industry has become a leading industry in recent years to support and drive the sustained and rapid growth of China's and even the world's economy. In the rapid development of new energy vehicles, one problem that must be solved is the problem of quickly charging the power battery inside to replenish energy.

[0003] At present, high-voltage direct current is often provided by an on-board charger to quickly charge the power battery, and the on-board charger also has branch outputs to provide power for air heating equipment, air-conditioning compressors, water heating equipment, etc. The number of branch outputs can be changed according to the needs of different models.

[0004] The on-board charger includes an on-board DC / DC converter to provide high-voltage direct current, such as high-voltage direct current with a voltage level of 400V or 800V. The high-voltage direct current is often output through a metal busbar. An OBC fuse (on-board charger fuse) 331 is often provided between the metal busbar and the DC charging interface connected to the power battery, so as to control the closing and closing of the OBC fuse 331 to realize whether to charge the power battery; a fuse is also often provided between the metal busbar and the load interface connected to each branch output, so as to respectively protect the air heating equipment, air conditioning compressor and water heating equipment, etc. In addition, each branch output also includes a wiring harness to connect the output of the fuse to the interface of the branch output.

[0005] The on-board charger often includes a high-voltage distribution box, which realizes the function of power distribution, electrically connects the high-voltage components through the above-mentioned metal bus and wiring harness, plays the role of power connection, and plays a protection function (such as short-circuit protection) through the above-mentioned fuse.

[0006] Therefore, the high-voltage distribution box is one of the key components of the on-board charger. Its reliability directly affects the reliability of the on-board charger, its integration directly affects the integration of the on-board charger, and its assembly complexity also directly affects the assembly complexity of the on-board charger.

[0007] For example, in the prior art, metal bars are usually fixed to the bracket 310 one by one by screws. Not only is the installation process cumbersome, but the connection strength between the metal bar and the bracket 310 is also relatively low, and may become loose or even fall off due to vibration, thermal deformation, aging, etc., affecting reliability. The fuse and the wiring harness may be integrated on the same bracket 310, or they may be fixed and connected by other means. However, they all have the problems of cumbersome installation, poor reliability, and low integration. Utility Model Content

[0008] The present application proposes a high-voltage distribution box for a vehicle charger, comprising:

[0009] A bracket, comprising a bottom plate, a top plate and a plurality of intermediate plates, wherein the plurality of intermediate plates are arranged between the bottom plate and the top plate along the length direction of the bottom plate and the top plate, and are vertically connected to the bottom plate and the top plate to form a two-layer bracket structure, wherein the length of the top plate is smaller than that of the bottom plate, so as to form a first accommodation space on one side of the top plate and above the bottom plate;

[0010] The OBC fuse, the DC metal bar positive terminal and the DC metal bar negative terminal are assembled on the bottom plate and accommodated in the first accommodation space, and the DC metal bar positive terminal and the DC metal bar negative terminal also extend out of the bracket;

[0011] At least one PDU branch fuse, mounted on the top plate;

[0012] A plurality of positive wiring harness terminals and a plurality of negative wiring harness terminals are mounted on the bottom plate.

[0013] The second end of the OBC fuse is connected to the first end of at least one PDU branch fuse in sequence through the positive metal bus, the second end of the OBC fuse is connected to the positive end of the DC metal bus, and the second end of at least one PDU branch fuse is connected to the power positive harness terminal through at least one intermediate positive metal bus, and the positive metal bus is also connected to the high-voltage positive harness terminal; the negative end of the DC metal bus, the power negative harness terminal and the high-voltage negative harness terminal are connected through the negative metal bus.

[0014] Furthermore, the positive end of the DC metal busbar is configured as a three-section structure, the second section connects the first section and the third section, the second section and the third section are both accommodated in the first accommodation space, and the first section extends out of the bracket.

[0015] Furthermore, a connection hole is provided on the third section of the positive end of the DC metal busbar, and a fixing member passes through the connection hole on the second end of the OBC fuse, the connection hole on the positive end of the DC metal busbar and the fixing hole on the base plate to fix the second end of the OBC fuse and the positive end of the DC metal busbar on the base plate.

[0016] Furthermore, the positive metal bar is configured as a three-section structure, the second section connects the first section and the third section, wherein the first section is placed on the top plate, at least one connection hole is provided on the first section, and the fixing member passes through the connection hole on the first end of the PDU branch fuse, the connection hole on the first section of the positive metal bar and the fixing hole on the top plate, so as to fix the first end of the PDU branch fuse and the positive metal bar on the top plate;

[0017] The third section is provided with a connection hole, and the fixing piece passes through the connection hole on the first end of the OBC fuse, the connection hole on the third section of the positive metal row and the fixing hole on the bottom plate, so as to fix the first end of the OBC fuse and the positive metal row on the bottom plate.

[0018] The first end of the OBC fuse and the first end of at least one PDU branch fuse are connected in sequence through the positive metal bar.

[0019] Furthermore, the middle positive metal bar is configured as a three-section structure, the second section connects the first section and the third section, wherein the first section and the third section are provided with connection holes, and the fixing member passes through the connection hole on the second end of the PDU branch fuse, the connection hole on the first section of the middle positive metal bar and the fixing hole on the top plate, so as to fix the second end of the PDU branch fuse and the first section of the middle positive metal bar on the top plate;

[0020] The fixing piece passes through the connection hole on the third section of the middle positive metal row, the connection hole on the power positive wire harness terminal and the fixing hole on the bottom plate, and fixes the power positive wire harness terminal and the third section of the middle positive metal row on the bottom plate.

[0021] The second end of at least one PDU branch fuse is respectively connected to the power positive harness terminal through at least one middle positive metal bar.

[0022] Furthermore, the third section and the second section of the positive metal bar are accommodated in the first accommodating space, and the positive metal bar also includes an extension portion extending from the third section, and a connecting hole is provided on the extension portion. The fixing part passes through the connecting hole on the extension portion, the connecting hole on the high-voltage positive wiring harness terminal and the fixing hole on the base plate to fix the high-voltage positive wiring harness terminal and the extension portion of the positive metal bar on the base plate.

[0023] Furthermore, the negative end of the DC metal bar is configured as a three-section structure, the second section connects the first section and the third section, the second section and the third section of the negative end of the DC metal bar are both accommodated in the first accommodation space, and the first section extends out of the bracket;

[0024] A connection hole is arranged on the third section of the negative end of the DC metal bar. A fixing piece passes through the connection hole on the third section of the negative end of the DC metal bar and the fixing hole on the bottom plate to fix the negative end of the DC metal bar on the bottom plate.

[0025] Furthermore, the negative metal bus has a strip structure with multiple lugs, wherein the lugs are provided with connection holes, and the fixing parts pass through the connection holes on the lugs, the connection holes on the high-voltage negative wiring harness terminals, the connection holes on the power negative wiring harness terminals and the fixing holes on the base plate to fix the high-voltage negative wiring harness terminals, the power negative wiring harness terminals and the negative metal bus on the base plate.

[0026] Furthermore, the high-voltage power positive wiring harness terminal is adjacent to the high-voltage negative wiring harness terminal, the power positive wiring harness terminal of the same PDU branch fuse is adjacent to the power negative wiring harness terminal, and the DC metal busbar positive terminal is adjacent to the DC metal busbar negative terminal.

[0027] An intermediate plate is arranged between adjacent power positive wiring harness terminals and power negative wiring harness terminals, and between adjacent high-voltage positive wiring harness terminals and high-voltage negative wiring harness terminals, as an insulating baffle; an intermediate plate is arranged between adjacent DC metal bus positive terminals and DC metal bus negative terminals, as an insulating baffle.

[0028] Furthermore, the bracket is provided with a plurality of openings on the second long side of the bottom plate to accommodate the high-voltage positive harness terminal, the power positive harness terminal, the high-voltage negative harness terminal, and the power negative harness terminal, and to extend them from the bracket;

[0029] The bracket also includes a side plate, which is connected to the first long side of the bottom plate, the first long side is opposite to the second long side, and the DC metal bar positive end and the DC metal bar negative end extend from the side of the side plate.

[0030] The present application also provides a vehicle-mounted charger, comprising: a cavity; a vehicle-mounted DC / DC converter module, housed in the cavity; the above-mentioned high-voltage distribution box, the high-voltage distribution box being housed in the cavity, wherein the high-voltage distribution box matches the vehicle-mounted DC / DC converter module in length and height.

[0031] Furthermore, a fixing hole is provided on the side panel of the high-voltage distribution box to fix the bracket on the vehicle-mounted DC / DC converter module.

[0032] The above is a fairly broad overview of the features and technical advantages of the present application, so that the following detailed description of the present application can be better understood. The additional features and advantages of the present application will be described below, and they form the subject matter of the claims of the present application. It will be appreciated by those skilled in the art that the disclosed concepts and specific embodiments can be easily utilized as the basis for modifying or designing other structures or processes for realizing the same purpose of the present application. It will also be appreciated by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the present application as set forth in the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] In order to more fully understand the present application and its advantages, reference is now made to the following description in conjunction with the accompanying drawings, in which:

[0034] Figure 1 The circuit diagram of the on-board charger is shown;

[0035] Figure 2 A schematic diagram of the structure of a vehicle charger according to an embodiment of the present application is shown;

[0036] Figure 3 A schematic diagram of a high-voltage distribution box applied to a vehicle charger according to an embodiment of the present application is shown;

[0037] Figure 4 Shows Figure 3 Exploded diagram of a high-voltage distribution box used in an on-board charger.

[0038] Corresponding numerals and symbols in the different figures generally refer to corresponding parts unless otherwise indicated.The figures are drawn to clearly illustrate the relevant aspects of the various embodiments and are not necessarily drawn to scale. DETAILED DESCRIPTION

[0039] Various exemplary embodiments, features and aspects of the present invention will be described in detail below with reference to the accompanying drawings. The same reference numerals in the accompanying drawings represent elements with the same or similar functions. Although various aspects of the embodiments are shown in the accompanying drawings, the drawings are not necessarily drawn to scale unless otherwise specified.

[0040] The word "exemplary" used herein means "serving as an example, embodiment or illustrative". Any embodiment described herein as "exemplary" is not necessarily to be interpreted as being superior or better than other embodiments. The terms "first", "second", "third", etc. (if any) in the specification and claims of the present utility model and the drawings are used to distinguish similar objects, and are not necessarily used to describe a specific order or sequence.

[0041] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "coupled", "connected", and "connected" should be understood in a broad sense. For example, it can be an electrical connection or mutual communication, it can be a direct connection, it can also be an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0042] In addition, in order to better illustrate the utility model, numerous specific details are given in the specific embodiments below. It should be understood by those skilled in the art that the utility model can also be implemented without certain specific details. In some examples, methods, means, components and circuits well known to those skilled in the art are not described in detail in order to highlight the main purpose of the utility model.

[0043] See also Figure 1The circuit diagram of the on-board charger shown in the figure, the on-board charger includes an on-board DC / DC converter 10 to provide high-voltage direct current Vout, such as 400V or 800V high-voltage direct current, and the high-voltage direct current Vout is connected to the DC charging interface d1 through the OBC fuse 331 to charge the power battery; the high-voltage direct current Vout is also connected to the load interfaces d2, d3 and d4 through the second PDU branch fuse K2 to the fourth PDU (high-voltage distribution) branch fuse K4 to respectively supply power to the air heating equipment, air conditioning compressor and water heating equipment, etc. The OBC fuse 331 and the second PDU branch fuse K2 to the fourth PDU branch fuse K4 play a role in controlling the power on and off, so as to determine whether to supply power, and also play a protective role.

[0044] As described in the prior art, the on-board DC / DC converter outputs high-voltage direct current through a metal busbar, and the metal busbar is connected to the interface through a wiring harness. In order to improve the integration of the on-board charger, in one embodiment of the present application, a high-voltage distribution box for an on-board charger is provided, which integrates a metal busbar (for connection with the output metal busbar of the on-board DC / DC converter), an OBC fuse 331, the second PDU branch fuse K2 to the fourth PDU branch fuse K4, and a wiring harness. In this way, the on-board charger only includes an on-board DC / DC converter module and a high-voltage distribution box to complete the functions of power conversion and power distribution.

[0045] For details, please refer to Figure 2 As shown in the schematic diagram of the structure of the on-board charger of an embodiment of the present application, the on-board charger structure includes a cavity 100, in which the on-board DC / DC converter module 200 and the high-voltage distribution box 300 provided in an embodiment of the present application are placed, and the high-voltage distribution box 300 is designed to match the length and height of the on-board DC / DC converter module 200, so that the space in the cavity can be fully utilized, the integration of the on-board charger is improved, and the volume of the on-board charger is reduced.

[0046] More preferably, the length of the high-voltage distribution box 300 is equal to the length of the vehicle-mounted DC / DC converter module 200, and the height of the high-voltage distribution box 300 is also equal to the height of the vehicle-mounted DC / DC converter module 200. In this way, the space in the cavity 100 can be optimally utilized. Of course, there may be slight deviations, such as being slightly smaller than the length and height of the vehicle-mounted DC / DC converter module 200.

[0047] In order to minimize the volume of the on-board charger, the width of the high-voltage distribution box 300 needs to be minimized, that is, the high-voltage distribution box 300 should be made into a slender structure as much as possible. In addition, the installation complexity needs to be reduced as much as possible to improve the degree of integration.

[0048] Based on the above, an embodiment of the present application further provides a high-voltage distribution box for a vehicle-mounted charger. Figure 3 A schematic diagram of a high-voltage distribution box applied to a vehicle charger according to an embodiment of the present application is shown, and Figure 4 shown Figure 3 Explosion diagram of the high-voltage distribution box used for on-board chargers. Figure 3 and Figure 4 As shown, the high-voltage distribution box 300 applied to the vehicle charger includes:

[0049] The bracket 310 includes a bottom plate 311, a top plate 312, and a plurality of middle plates 313, wherein the plurality of middle plates 313 are arranged between the bottom plate 311 and the top plate 312 along the length direction of the bottom plate 311 and the top plate 312, and are vertically connected to the bottom plate 311 and the top plate 312 to form a two-layer bracket structure, wherein the length of the top plate 312 is smaller than that of the bottom plate 311, so as to form a first accommodation space 320 on one side of the top plate 312 and above the bottom plate 311;

[0050] The OBC fuse 331, the DC metal bar positive terminal 340 and the DC metal bar negative terminal 350 are mounted on the bottom plate 311 and accommodated in the first accommodation space 320, and the DC metal bar positive terminal 340 and the DC metal bar negative terminal 350 also extend out of the bracket 310;

[0051] At least one PDU branch fuse 332, 333, 334, mounted on the top plate 312;

[0052] A plurality of positive wiring harness terminals 361, 362, 363, 364 and a plurality of negative wiring harness terminals 371, 372, 373, 374 are mounted on the bottom plate 311.

[0053] The second end a2 of the OBC fuse 331 is connected in sequence to the first end b1 of at least one PDU branch fuse 332, 333, 334 through the positive metal bar 380, the second end a2 of the OBC fuse 331 is connected to the DC metal bar positive end 340, and the second end b2 of at least one PDU branch fuse 332, 333, 334 is respectively connected to the power positive harness terminal 362, 363, 364 through at least one intermediate positive metal bar 384, 385, 386, the positive metal bar 380 is also connected to the high-voltage positive harness terminal 361; the DC metal bar negative end 350, the power negative harness terminals 372, 373, 374 and the high-voltage negative harness terminal 371 are connected through the negative metal bar 388, wherein the metal bar is non-detachably fixed in the bracket 310.

[0054] like Figure 3 and 4As shown, the bracket 310 forms an upper and lower stacked structure, and components can be installed on both the upper and lower layers, thereby increasing the space for installing devices and matching the height of the vehicle-mounted DC / DC converter module 200. The width of the bracket 310 is minimized on the basis of fully utilizing the height space in the cavity 100.

[0055] As mentioned above, the metal bar, OBC fuse 331, PDU branch fuses 332, 333, 334, and wiring harness that realize the function of the high-voltage distribution box are integrated on the bracket 310, that is, the high-voltage distribution box is integrated into one part, which undoubtedly improves the integration of the high-voltage distribution box, and can also reduce the safety requirement area and shorten the installation process to achieve integration. In addition, the metal bar is non-detachably fixed in the bracket 310, which increases the fixing and connection strength of the metal bar and improves the reliability of the high-voltage distribution box, which is particularly suitable for occasions where the metal bar does not need to be replaced.

[0056] In one embodiment of the present application, the metal bar is fixed in the bracket 310 by injection molding, glue bonding, etc. During implementation, the gap between the metal bar and the bracket 310 is filled with injection molding material or glue, and only the connection holes on the metal bar are exposed, and other areas are covered with plastic. The metal bar has high fixing and connection strength, and will not loosen or even fall off due to vibration, thermal deformation, aging, etc. In addition, during assembly, all metal bars are placed in the predetermined position first, and then the whole is injected or filled with glue, which can make the installation simple and the degree of integration high.

[0057] In actual implementation, the bracket 310 is made of plastic material, which can have better insulation properties and reduce the risk of leakage when the metal bus is working with current.

[0058] In actual implementation, the metal busbar can be made of any metal material, such as a copper busbar.

[0059] Please continue reading Figure 3 and Figure 4 The DC metal bar positive terminal 340 is configured as a three-section structure, and the second section 342 connects the first section 341 and the third section 343, both forming a stepped structure as a whole. The second section 342 and the third section 343 of the DC metal bar positive terminal 340 are both accommodated in the first accommodation space 320, and the first section 341 extends out of the bracket 310 to be connected to the metal bar of the vehicle-mounted DC / DC converter module 200 to achieve power transmission.

[0060] Please continue reading Figure 3 and Figure 4 , and please combine Figure 1A connection hole is provided on the third section 343 of the DC metal bar positive terminal 340, wherein a fixing piece passes through the connection hole on the second end a2 of the OBC fuse 331, the connection hole of the DC metal bar positive terminal 340 and the fixing hole on the bottom plate 311, so as to fix the second end a2 of the OBC fuse 331 and the DC metal bar positive terminal 340 on the bottom plate 311, and realize the electrical connection between the DC metal bar positive terminal 340 and the OBC fuse 331.

[0061] In specific implementation, Figure 4 As shown, the third section of the DC metal bar positive terminal 340 further includes a bending portion 3431 extending toward the second end a2 of the OBC fuse 331 , and the connection hole of the DC metal bar positive terminal 340 is disposed on the bending portion 3431 .

[0062] For specific implementation, please refer to Figure 3 and Figure 4 The positive metal row 380 is configured as a three-section structure, and the second section 382 connects the first section 381 and the third section 383 to form an overall stepped structure. The first section 381 is placed on the top plate 312, and at least one connecting hole is provided on the first section 381. The fixing piece passes through the connecting hole on the first end b1 of the PDU branch fuses 332, 333, 334, the connecting hole on the first section 381 of the positive metal bar 380, and the fixing hole on the top plate 312, so as to fix the first end b1 of the PDU branch fuses 332, 333, 334 and the positive metal bar 380 on the top plate 312; the third section 383 is provided with a connecting hole, and the fixing piece passes through the connecting hole on the first end a1 of the OBC fuse 331, the connecting hole on the third section 383 of the positive metal bar 380, and the fixing hole on the bottom plate 311, so as to fix the first end a1 of the OBC fuse 331 and the positive metal bar 380 on the bottom plate 311, and the first end a1 of the OBC fuse 331 and the first end b1 of at least one PDU branch fuse 332, 333, 334 are connected in sequence through the positive metal bar 380. In actual implementation, the number of connection holes on the first section of the positive metal bar 380 corresponds to the number of PDU branch fuses, such as Figure 3 and 4 As shown, there are three PDU branch fuses, and the corresponding first section of the positive metal row 380 has three connection holes, and the corresponding top plate 312 also has three fixing holes.

[0063] For specific implementation, please refer to Figure 3 and Figure 4The middle positive metal bars 384, 385, and 386 are also configured as a three-section structure, and the second section connects the first section and the third section to form an overall stepped structure, wherein the first section and the third section are provided with connecting holes, and the fixing parts pass through the connecting holes on the second ends b2 of the PDU branch fuses 332, 333, and 334, the connecting holes on the first sections of the middle positive metal bars 384, 385, and 386, and the fixing holes on the top plate 312, so as to fix the second ends b2 of the PDU branch fuses 332, 333, and 334 and the first sections of the middle positive metal bars 384, 385, and 386 on the top plate 312. The fixing member passes through the connection holes on the third section of the middle positive metal bars 384, 385, 386, the connection holes on the power positive harness terminals 362, 363, 364 and the fixing holes on the bottom plate 311, and fixes the power positive harness terminals 362, 363, 364 and the third section of the middle positive metal bars 384, 385, 386 on the bottom plate 311. In this way, the second end b2 of at least one PDU branch fuse 332, 333, 334 is connected to the power positive harness terminals 362, 363, 364 through at least one middle positive metal bar 384, 385, 386. In actual implementation, the number of the middle positive metal bars 384, 385, 386 and the power positive harness terminals 362, 363, 364 corresponds to the number of the PDU branch fuses, such as Figure 3 and 4 As shown, there are three PDU branch fuses, and correspondingly there are three middle positive metal bars 384, 385, 386 and three power positive wire harness terminals 362, 363, 364, so as to realize one-to-one connection and realize the connection between the upper and lower layers of devices. The above-mentioned power positive wire harness terminals 362, 363, 364 can be used for connecting Figure 1 and Figure 2 Positive wiring harness terminal of load interfaces D2, D3 and D4.

[0064] For specific implementation, please refer to Figure 3 and Figure 4 , the third section 383 and the second section 382 of the positive metal bar 380 are accommodated in the first accommodation space 320, and the first end extends to the top plate 312. More specifically, in a specific implementation, the positive metal bar 380 also includes an extension portion 387 extending from the third section 383, and a connecting hole is provided on the extension portion 387. The fixing member passes through the connecting hole on the extension portion 387, the connecting hole on the high-voltage positive wiring harness terminal 361, and the fixing hole on the bottom plate 311 to fix the high-voltage positive wiring harness terminal 361 and the extension portion 387 of the positive metal bar 380 on the bottom plate 311. The high-voltage positive wiring harness terminal 361 can be used as a connection Figure 1 and Figure 2 The high voltage positive wiring harness terminal of the DC charging interface d1 in FIG. Figure 4As shown, the extension portion 387 extending from the third section 383 includes a first section extending toward the bottom plate 311, a second end parallel to the bottom plate 311, a third section extending away from the bottom plate 311, and a fourth section parallel to the bottom plate 311, wherein a connecting hole is formed on the fourth section.

[0065] like Figure 3 and Figure 4 As shown, the top plate 312 can be implemented as a non-continuous plate-like structure as long as it can carry the PDU branch fuse and is provided with the required fixing holes as mentioned above, as well as holes, holes or hollow areas for the middle positive metal rows 384, 385, 386 to span from the top plate 312 to the bottom plate 311.

[0066] For specific implementation, please refer to Figure 3 and Figure 4 Similar to the structure of the positive metal bar 380, the negative DC metal bar 350 is configured as a three-section structure, and the second section 352 connects the first section 351 and the third section 353, both forming a stepped structure as a whole. The second section 352 and the third section 353 of the negative DC metal bar 350 are both accommodated in the first accommodation space 320, and the first section 351 extends out of the bracket 310 to be connected to the metal bar of the vehicle-mounted DC / DC converter module 200 to achieve power transmission.

[0067] Please continue reading Figure 3 and Figure 4 , and please combine Figure 1 A connection hole is provided on the third section 353 of the DC metal bar negative terminal 350 , wherein a fixing piece passes through the connection hole on the third section 353 of the DC metal bar negative terminal 350 and the fixing hole on the bottom plate 311 to fix the DC metal bar negative terminal 350 on the bottom plate 311 .

[0068] For specific implementation, please refer to Figure 3 and Figure 4 The negative metal bar 388 is implemented as a strip structure with a plurality of lugs, wherein the lugs are provided with connection holes, and the fixing parts pass through the connection holes on the lugs, the connection holes on the high-voltage negative wiring harness terminal 371, the connection holes on the power negative wiring harness terminals 372, 373, 374, and the fixing holes on the bottom plate 311, so as to fix the high-voltage negative wiring harness terminal 371, the power negative wiring harness terminals 372, 373, 374 and the negative metal bar 388 on the bottom plate 311, wherein the high-voltage negative wiring harness terminal 371 is used for connecting Figure 1 and Figure 2 The power negative wiring harness terminal of the DC charging interface d1 in the embodiment of the present invention, wherein the three power negative wiring harness terminals 372, 373, and 374 are respectively used for connecting Figure 1 and Figure 2 The power negative wiring terminal of the load interface D2, D3 and D4.

[0069] The high-voltage power positive harness terminal 361 of the DC charging interface d1 is adjacent to the high-voltage negative harness terminal 371, and the power positive harness terminals 362, 363, 364 of the same PDU branch fuse are adjacent to the power negative harness terminals 372, 373, 374 to form a port structure.

[0070] For specific implementation, please refer to Figure 3 and Figure 4 The bracket 310 is provided with a plurality of openings on the second long side of the bottom plate 311 to accommodate the high-voltage positive harness terminal 361, the power positive harness terminals 362, 363, 364, the high-voltage negative harness terminal 371, and the power negative harness terminals 372, 373, 374, and to extend them from the bracket 300. In addition, the above-mentioned intermediate plate 313 is provided between the power positive harness terminals 362, 363, 364 and the power negative harness terminals 372, 373, 374, and between the high-voltage positive harness terminal 361 and the high-voltage negative harness terminal 371 to serve as a baffle to achieve insulation between the positive harness terminals 361, 362, 363, 364 and the negative harness terminals 372, 373, 374. Furthermore, an intermediate plate 313 is also provided between the DC metal bar positive terminal 340 and the DC metal bar negative terminal 350 to achieve mutual insulation.

[0071] In a specific implementation, the crimping terminals (ie, terminals with connecting holes) of the positive harness terminals 361, 362, 363, 364 and the negative harness terminals 372, 373, 374 are waist-shaped holes, which can absorb the tolerance of the harness length and facilitate assembly.

[0072] For specific implementation, please refer to Figure 3 and Figure 4 The bracket 310 further includes a side plate 390, which is connected to the first long side of the bottom plate 311, and the first long side is opposite to the second long side. In a specific implementation, the negative metal bar 388 is close to the side plate 390 and is arranged parallel to the side plate 390, so that the lugs on it extend toward the second long side of the bottom plate 311. Specifically, the negative metal bar 388 is parallel to the side plate 390 in the width direction to reduce the width of the high-voltage distribution box.

[0073] in this way Figure 3 The high voltage distribution box structure shown has Figure 1 The circuit connection relationship of the on-board charger shown in the figure can manage the high-voltage power distribution of the whole vehicle and realize the control and protection of each output separately. It has high integration and integration, simple assembly and high reliability.

[0074] As described above, the DC metal bar positive end 340 and the positive metal bar 380, and the positive metal bar 380 and the middle positive metal bars 384, 385, 386 are connected by fuses, forming the positive circuit of the fuse holder 310. The DC metal bar negative end 350 and the negative metal bar 388 form the negative circuit of the fuse holder 310, and the metal bars and the fuses, and the metal bars are connected by locking, such as by screws and nuts.

[0075] For specific implementation, please refer to Figure 3 and Figure 4 The bottom plate 311 may not be a flat plate structure, and may be provided with protrusions or depressions to match the devices disposed thereon and to connect the devices through the shortest copper bar. For example, the height of the bottom plate in the first accommodation space 320 may be higher than the height of the bottom plates in other areas.

[0076] During specific implementation, some reinforcing ribs may be designed on the bottom plate 311 to increase stability.

[0077] Furthermore, Figure 3 As shown, the upper PDU branch fuses 332, 333, 334, the lower pair of power positive harness terminals 362, 363, 364 and power negative harness terminals 372, 373, 374 form a high-voltage output, the upper OBC fuse 331, the lower pair of high-voltage positive harness terminals 361 and high-voltage negative harness terminals 371 form a high-voltage output, and the multiple outputs are arranged in sequence. Figure 3 As shown, the upper PDU branch fuses 332, 333, 334 are arranged in the length direction of the bracket to minimize the required width of the bracket 300. In actual implementation, the upper PDU branch fuses 332, 333, 334 may have a certain angle with the length direction of the bracket.

[0078] In actual implementation, the number of upper PDU branch fuses, a pair of lower power positive wiring terminals, and negative power wiring terminals can be adjusted according to the number of high-voltage outputs required, and the number of high-voltage outputs can be flexibly adjusted, making the design simpler, similar to the stacking method of building blocks. Figure 3 and Figure 4 The bracket structure is described by taking three PDU branch fuses as an example. The three PDU branch fuses 332, 333, and 334 correspond to Figure 1 The second PDU branch fuse K2 to the fourth PDU branch fuse K4 play a role in controlling the power on-off to determine whether to supply power, and also play a protective role.

[0079] For actual implementation, see Figure 2 and Figure 3The DC metal bar positive terminal 340 and the DC metal bar negative terminal 350 extend from the side plate 390 to the vehicle-mounted DC / DC converter module 200 to be connected to the copper bar in the vehicle-mounted DC / DC converter module 200. In actual implementation, the side plate 390 is provided with a fixing hole (not shown in the figure) to fix the bracket 310 on the vehicle-mounted DC / DC converter module 200, so that the vehicle-mounted DC / DC converter module 200 and the high-voltage distribution box together form a vehicle-mounted charger with a small size and simple assembly.

[0080] In one embodiment of the present application, a method for assembling the above-mentioned high-voltage distribution box is also provided, which can be referred to in Figure 3 and Figure 4 ,include:

[0081] A bracket 310 is provided, comprising a bottom plate 311, a top plate 312 and a plurality of intermediate plates 313, wherein the plurality of intermediate plates 313 are arranged between the bottom plate 311 and the top plate 312 along the length direction of the bottom plate 311 and the top plate 312, and are vertically connected to the bottom plate 311 and the top plate 312 to form a two-layer bracket 310 structure, wherein the length of the top plate 312 is smaller than the length of the bottom plate 311, so as to form a first accommodation space 320 on one side of the top plate 312 and above the bottom plate 311;

[0082] An OBC fuse 331, a DC metal bar positive terminal 340, a DC metal bar negative terminal 350, at least one PDU branch fuse 332, 333, 334, a positive metal bar 380, at least one middle positive metal bar 384, 385, 386, a negative metal bar 388, a plurality of power positive wiring harness terminals 362, 363, 364, a plurality of power negative wiring harness terminals 372, 373, 374, a high-voltage positive wiring harness terminal 361, a high-voltage negative wiring harness terminal 371, and a fixing member are provided. The OBC fuse 331, the DC metal bar positive terminal 340 and the DC metal bar negative terminal 350 are assembled on the bottom plate 311 through the fixing member and accommodated in the first accommodation space 320. At least one PDU branch fuse 332, 333, 334 is assembled on the top plate 312. The plurality of power positive wiring harness terminals 362, 363, 364 are assembled on the top plate 312. 64. A plurality of power positive harness terminals 372, 373, 374, a high-voltage positive harness terminal 361, and a high-voltage negative harness terminal 371 are assembled on the bottom plate 311, and during assembly, the first end a1 of the OBC fuse 331 and the first end b1 of at least one PDU branch fuse 332, 333, 334 are sequentially connected through the positive metal bar 380, the second end a2 of the OBC fuse 331 is connected to the DC metal bar positive end 340, and the second end b2 of at least one PDU branch fuse 332, 333, 334 is respectively connected to the power positive harness terminals 362, 363, 364 through at least one intermediate positive metal bar 384, 385, 386; the DC metal bar negative end 350 and the power negative harness terminals 372, 373, 374 and the high-voltage negative harness terminal 371 are connected through the negative metal bar 388;

[0083] The space in the bracket 310 is filled by injection molding or adhesive bonding, and the DC metal bar positive terminal 340 and the DC metal bar negative terminal 350 extending from the bracket 300 are exposed.

[0084] Its advantages are the same as above and will not be repeated here.

[0085] Although the embodiments of the present application and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the application as defined by the appended claims.

[0086] In addition, the scope of the present application is not limited to the specific embodiments of the processes, machines, manufactures, material compositions, modes, methods, and steps described in this specification. Those skilled in the art will readily understand from the disclosure of the present application that, according to the present application, currently existing or later to be developed processes, machines, manufactures, material compositions, modes, methods, or steps that perform substantially the same functions or achieve substantially the same results as the corresponding embodiments described herein may be utilized. Therefore, it is intended that the appended claims include such processes, machines, manufactures, material compositions, modes, methods, or steps within their scope.

Claims

1. A high-voltage distribution box for a vehicle charger, characterized in that: include: A bracket, comprising a bottom plate, a top plate and a plurality of intermediate plates, wherein the plurality of intermediate plates are arranged between the bottom plate and the top plate along the length direction of the bottom plate and the top plate, and are vertically connected to the bottom plate and the top plate to form a two-layer bracket structure, wherein the length of the top plate is smaller than that of the bottom plate, so as to form a first accommodation space on one side of the top plate and above the bottom plate; The OBC fuse, the DC metal bar positive terminal and the DC metal bar negative terminal are assembled on the bottom plate and accommodated in the first accommodation space, and the DC metal bar positive terminal and the DC metal bar negative terminal also extend out of the bracket; At least one PDU branch fuse, mounted on the top plate; A plurality of positive wiring harness terminals and a plurality of negative wiring harness terminals are mounted on the bottom plate. The second end of the OBC fuse is connected to the first end of at least one PDU branch fuse in sequence through the positive metal bus, the second end of the OBC fuse is connected to the positive end of the DC metal bus, and the second end of at least one PDU branch fuse is connected to the power positive harness terminal through at least one intermediate positive metal bus, and the positive metal bus is also connected to the high-voltage positive harness terminal; the negative end of the DC metal bus, the power negative harness terminal and the high-voltage negative harness terminal are connected through the negative metal bus.

2. The high-voltage distribution box for a vehicle charger according to claim 1 is characterized in that: The positive end of the DC metal busbar is configured as a three-section structure, the second section connects the first section and the third section, the second section and the third section are both accommodated in the first accommodation space, and the first section extends out of the bracket.

3. The high-voltage distribution box for a vehicle charger according to claim 2 is characterized in that: A connection hole is provided on the third section of the positive end of the DC metal bar. A fixing piece passes through the connection hole on the second end of the OBC fuse, the connection hole on the positive end of the DC metal bar and the fixing hole on the bottom plate to fix the second end of the OBC fuse and the positive end of the DC metal bar on the bottom plate.

4. The high-voltage distribution box for a vehicle charger according to claim 1, characterized in that: The positive metal bar is configured as a three-section structure, the second section connects the first section and the third section, wherein the first section is placed on the top plate, at least one connection hole is provided on the first section, and the fixing member passes through the connection hole on the first end of the PDU branch fuse, the connection hole on the first section of the positive metal bar and the fixing hole on the top plate, so as to fix the first end of the PDU branch fuse and the positive metal bar on the top plate; The third section is provided with a connection hole, and the fixing piece passes through the connection hole on the first end of the OBC fuse, the connection hole on the third section of the positive metal row and the fixing hole on the bottom plate, so as to fix the first end of the OBC fuse and the positive metal row on the bottom plate. The first end of the OBC fuse and the first end of at least one PDU branch fuse are connected in sequence through the positive metal bar.

5. The high-voltage distribution box for a vehicle-mounted charger according to claim 4 is characterized in that: The middle positive metal bar is configured as a three-section structure, the second section connects the first section and the third section, wherein the first section and the third section are provided with connection holes, and the fixing piece passes through the connection hole on the second end of the PDU branch fuse, the connection hole on the first section of the middle positive metal bar and the fixing hole on the top plate, so as to fix the second end of the PDU branch fuse and the first section of the middle positive metal bar on the top plate; The fixing piece passes through the connection hole on the third section of the middle positive metal row, the connection hole on the power positive wire harness terminal and the fixing hole on the bottom plate, and fixes the power positive wire harness terminal and the third section of the middle positive metal row on the bottom plate. The second end of at least one PDU branch fuse is respectively connected to the power positive harness terminal through at least one middle positive metal bar.

6. The high-voltage distribution box for a vehicle charger according to claim 4 is characterized in that: The third section and the second section of the positive metal bar are accommodated in the first accommodating space. The positive metal bar also includes an extension portion extending from the third section. A connecting hole is provided on the extension portion. The fixing piece passes through the connecting hole on the extension portion, the connecting hole on the high-voltage positive wiring harness terminal and the fixing hole on the base plate to fix the high-voltage positive wiring harness terminal and the extension portion of the positive metal bar on the base plate.

7. The high-voltage distribution box for a vehicle charger according to claim 1, characterized in that: The negative end of the DC metal bar is configured as a three-section structure, the second section connects the first section and the third section, the second section and the third section of the negative end of the DC metal bar are both accommodated in the first accommodation space, and the first section extends out of the bracket; A connection hole is arranged on the third section of the negative end of the DC metal bar. A fixing piece passes through the connection hole on the third section of the negative end of the DC metal bar and the fixing hole on the bottom plate to fix the negative end of the DC metal bar on the bottom plate.

8. The high-voltage distribution box for a vehicle charger according to claim 7, characterized in that: The negative metal busbar has a strip structure with multiple lugs, wherein the lugs are provided with connection holes, and the fixing parts pass through the connection holes on the lugs, the connection holes on the high-voltage negative wiring harness terminals, the connection holes on the power negative wiring harness terminals and the fixing holes on the base plate to fix the high-voltage negative wiring harness terminals, the power negative wiring harness terminals and the negative metal busbar on the base plate.

9. The high-voltage distribution box for a vehicle charger according to claim 1, characterized in that: The high-voltage power positive wiring harness terminal is adjacent to the high-voltage negative wiring harness terminal, the power positive wiring harness terminal of the same PDU branch fuse is adjacent to the power negative wiring harness terminal, and the DC metal busbar positive terminal is adjacent to the DC metal busbar negative terminal. An intermediate plate is arranged between adjacent power positive wiring harness terminals and power negative wiring harness terminals, and between adjacent high-voltage positive wiring harness terminals and high-voltage negative wiring harness terminals, as an insulating baffle; an intermediate plate is arranged between adjacent DC metal bus positive terminals and DC metal bus negative terminals, as an insulating baffle.

10. The high-voltage distribution box for a vehicle charger according to claim 1, characterized in that: The bracket is provided with a plurality of openings on the second long side of the bottom plate to accommodate the high-voltage positive wiring harness terminal, the power positive wiring harness terminal, the high-voltage negative wiring harness terminal, and the power negative wiring harness terminal, and to extend them from the bracket; The bracket also includes a side plate, which is connected to the first long side of the bottom plate, the first long side is opposite to the second long side, and the DC metal bar positive end and the DC metal bar negative end extend from the side of the side plate.

11. A vehicle-mounted charger, characterized in that: include: Cavity; The vehicle-mounted DC / DC converter module is accommodated in the cavity; The high-voltage distribution box described in any one of claims 1 to 10 is accommodated in a cavity, wherein the high-voltage distribution box matches the vehicle-mounted DC / DC converter module in length and height.

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