BDU fixing system, battery pack and new energy commercial vehicle

Abstract

The utility model relates to a BDU fixing system, a battery pack and a new energy commercial vehicle. The system comprises a BDU fixing tray, a fixing support and a damping assembly arranged between the BDU fixing tray and the fixing support. The BDU fixing tray is of an integrated structure and is used for installing and fixing a BDU. An annular shell is arranged at the upper end of the fixing support and used for containing and being connected with the damping assembly, and the lower end of the fixing support is used for being connected with a frame ventral face. The damping assembly comprises an upper shell, an upper stud, damping rubber and a lower stud, a plurality of protruding parts and groove parts are arranged in the circumferential direction of the damping rubber, the protruding parts and the groove parts extend in parallel to the axial direction of the damping rubber and are arranged at intervals, the outer diameter limited by the protruding parts is matched with the inner diameter of the annular shell, and the damping rubber is in transition fit with the annular shell. The overall weight of the BDU fixing system can be greatly reduced, and meanwhile the requirements for reliability and durability of the whole vehicle are met.

Description

Technical Field

[0001] The utility model relates to the technical field of power batteries for new energy vehicles, and in particular to a BDU fixing system and a new energy commercial vehicle. Background Art

[0002] BDU (Battery Disconnect Unit) is a battery pack disconnect unit designed specifically for the interior of a battery pack. As a device that disconnects and connects high voltage electricity to the battery pack of new energy vehicles, it plays a vital role in the safety of the battery pack.

[0003] The existing BDU fixing system assembly is mainly composed of a truss assembly 10, a shock absorbing pad assembly 20 and a fixing bracket 70', as shown in Figure 1 — Figure 5 , wherein the truss assembly 10 is welded from rectangular tubes and is used to directly fix the BDU assembly, such as Figure 2 The shock-absorbing pad assembly 20 is vulcanized by rubber 30 and an upper shell 40', an upper stud 50', a lower stud 60', and a fixing bracket 70', and is used for shock absorption between the truss assembly 10 and the fixing bracket 70'; the fixing bracket 70' is a cast aluminum part with a ring structure designed on the top for installing the shock-absorbing pad assembly 20.

[0004] During production and use, technicians found that the existing BDU fixing system has the following main shortcomings:

[0005] 1. The truss assembly 10 is generally welded from rectangular tubes, which has many welds and is heavy. Many welds make it difficult to ensure the accuracy of the parts, and the rectangular tubes used make the truss heavier, about 9.6 kg.

[0006] 2. The shock-absorbing pad assembly 20 lacks a shock-absorbing structure in the XY direction, which causes the fixing bracket 70' to be subjected to excessive force and break under the torsion condition of the vehicle.

[0007] In summary, the existing BDU fixing system assembly is not only heavy, but the reliability of the entire system cannot meet the reliability and durability requirements of the entire vehicle. Utility Model Content

[0008] The utility model discloses a BDU fixing system, a battery pack and a new energy commercial vehicle, aiming to solve the technical problems existing in the prior art.

[0009] The utility model adopts the following technical solutions:

[0010] On the one hand, an embodiment of the utility model provides a BDU fixing system, including a BDU fixing tray, a fixing bracket, and a shock absorbing assembly disposed therebetween;

[0011] The BDU fixing tray includes an integral structure made of continuous fiber reinforced thermoplastic unidirectional prepreg tape composite, which is used to install and fix the BDU;

[0012] The upper end of the fixed bracket is provided with an annular housing for accommodating and connecting the shock absorbing assembly, and the lower end of the fixed bracket is used to connect with the belly surface of the frame;

[0013] The shock absorbing assembly includes an upper shell, an upper stud, a shock absorbing rubber, a gasket and a lower stud. The upper end of the shock absorbing rubber is vulcanized and connected to the upper shell and the upper stud, and the lower end of the shock absorbing rubber is vulcanized and connected to the lower stud and the gasket. The upper stud is used to be fixedly connected to the BDU fixed tray, and the lower stud is used to be fixedly connected to the fixed bracket.

[0014] As a preferred technical solution, the shock-absorbing rubber is provided with a plurality of raised portions and groove portions in the circumferential direction. Both the raised portions and the groove portions extend parallel to the axial direction of the shock-absorbing rubber and are arranged at intervals. The outer diameter defined by the raised portions matches the inner diameter of the annular shell, and the shock-absorbing rubber and the annular shell are transitionally matched.

[0015] As a preferred technical solution, the cross section of the shock-absorbing rubber is gear-shaped, and a plurality of grooves are equidistantly distributed along the circumference of the shock-absorbing rubber.

[0016] As a preferred technical solution, a gasket is provided between the lower end of the shock-absorbing rubber and the head of the lower stud, the lower end of the shock-absorbing rubber is vulcanized and connected to the lower stud and the gasket, and the upper end of the shock-absorbing rubber is vulcanized and connected to the upper shell and the upper stud;

[0017] The lower stud is used to be fixedly connected to the fixing bracket, and the upper stud is used to be fixedly connected to the BDU fixing tray.

[0018] As a preferred technical solution, the lower end of the upper stud extends into the middle of the shock-absorbing rubber, and an annular supporting element is provided on the outer periphery of the lower end of the upper stud.

[0019] As a preferred technical solution, the annular support element is arranged between the head of the upper stud and the bottom surface of the upper shell, the length of the annular support element is the same as the length of the upper stud extending downward, the inner diameter of the annular support element matches the outer diameter of the upper stud, and the annular support element is an annular metal sleeve.

[0020] As a preferred technical solution, the BDU fixed tray is integrally hot-pressed.

[0021] As a preferred technical solution, the upper surface and / or lower surface of the BDU fixed tray is covered with a curtain layer.

[0022] As a preferred technical solution, the cross section of the BDU fixed tray includes at least one "X"-shaped structure.

[0023] On the other hand, an embodiment of the present invention provides a battery pack, which includes a BDU fixing system as described in any one of the above items.

[0024] In addition, an embodiment of the utility model also provides a new energy commercial vehicle, including the battery pack as described above.

[0025] One embodiment of the above utility model has the following advantages or beneficial effects:

[0026] The utility model mainly provides a BDU fixing system, which is suitable for pure electric heavy-duty commercial trucks. Compared with the prior art, the utility model designs the shock-absorbing rubber in the shock-absorbing assembly into a gear-shaped structure, with an upper shell and an upper stud vulcanized at the upper end, and a lower stud and a gasket vulcanized at the lower end. An annular support element is added between the upper stud and the shock-absorbing rubber to increase the participation of the rubber in shock absorption when the upper stud is subjected to radial load, while reducing the limit stroke between the upper stud and the lower stud. On the other hand, an annular support element is added in the Z direction to achieve effective limit in the Z direction, and the upper shell is effectively limited in the XY direction (360° radially) by the annular shell.

[0027] Furthermore, there is a transition fit between the shock-absorbing rubber and the annular shell, and the gap between the shock-absorbing rubber and the annular shell (i.e., the groove portion of the gear-shaped shock-absorbing rubber) is evenly distributed over the entire circumference. When the upper stud of the shock-absorbing assembly is subjected to a radial load in a 360° direction, the gear-shaped shock-absorbing rubber creeps and fills the preset gap, thereby effectively absorbing the load.

[0028] In addition, the BDU fixed tray, which serves as a load-bearing structure, adopts the structure of "CFRT composite material + heat-covered curtain fabric layer" and is hot-pressed. Due to the characteristics of its own materials, the CFRT composite material tray not only has load-bearing capacity, but also can absorb part of the load energy to play a certain shock-absorbing role, while greatly reducing the weight of the system. The weight of the CFRT composite material BDU fixed tray is only 3.0kg, which is 6.6kg lighter than the truss, a weight reduction of 68.8%. At the same time, it can also meet the reliability and durability requirements of the vehicle. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] In order to more clearly illustrate the technical solution of the embodiment of the utility model, the following is a brief introduction to the drawings required for the description of the embodiment, which constitute a part of the utility model. The schematic embodiment of the utility model and its description explain the utility model and do not constitute an improper limitation of the utility model. In the drawings:

[0030] Figure 1 It is a structural schematic diagram of a BDU fixing system in the prior art;

[0031] Figure 2It is a structural schematic diagram of a truss assembly in the prior art;

[0032] Figure 3 It is a top view of a shock-absorbing pad assembly in the prior art;

[0033] Figure 4 It is a cross-sectional view of a shock-absorbing pad assembly in the prior art;

[0034] Figure 5 It is a partial structural schematic diagram of a shock-absorbing pad assembly in the prior art;

[0035] Figure 6 This is a schematic diagram of the structure of the BDU fixing system disclosed in Example 1 of the utility model;

[0036] Figure 7 This is a structural exploded view of the BDU fixing system disclosed in Example 2 of the present utility model;

[0037] Figure 8 This is a schematic diagram of the structure of the BDU fixed tray disclosed in Example 1 of the utility model;

[0038] Fig. 9 A top view of the shock absorbing assembly disclosed in Example 1 of the utility model;

[0039] Fig.10 It is a cross-sectional view of the shock absorbing assembly disclosed in Example 1 of the utility model;

[0040] Fig.11 It is a partial structural schematic diagram of the shock absorbing assembly disclosed in Example 1 of the utility model;

[0041] Fig.12 It is a top view of the shock-absorbing rubber disclosed in Example 1 of the utility model;

[0042] Fig.13 This is a schematic diagram of the structure of the fixing bracket disclosed in Example 1 of the utility model.

[0043] Description of reference numerals:

[0044] Truss assembly 10, shock-absorbing pad assembly 20, rubber 30, upper shell 40, 40', upper studs 50, 50', annular support element 51, lower studs 60, 60', fixing brackets 70, 70', annular shell 71, BDU fixing tray 80, "J" shaped structure 81, shock-absorbing rubber 90, protrusion 91, groove 92. DETAILED DESCRIPTION

[0045] In order to make the purpose, technical solution and advantages of the utility model clearer, the technical solution of the utility model will be clearly and completely described below in combination with the specific embodiments of the utility model and the corresponding drawings. In the description of the utility model, it should be noted that the term "or" is usually used in the sense of including "and / or", unless the content clearly indicates otherwise.

[0046] In the description of the present utility model, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be internal communication between two components. For ordinary technicians in this field, the specific meanings of the above terms in the present utility model can be understood according to specific circumstances. In addition, in the description of this application, the terms "first", "second", etc. are only used to distinguish the description and cannot be understood as indicating or implying relative importance.

[0047] Obviously, the described embodiments are only some embodiments of the utility model, not all embodiments. Based on the embodiments of the utility model, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the utility model.

[0048] Example 1

[0049] The present embodiment provides a BDU fixing system for reliably fixing the BDU to avoid displacement due to vibration or impact; in the present embodiment, BDU (Battery Disconnect Unit) refers to a battery pack disconnect unit, which is integrated in the battery pack and includes components such as relays, fuses, pre-charge resistors, current sensors, etc., and uses copper busbars as a medium for carrying large currents, and uses cables or PCBs as a medium for carrying small currents and communication control signals; the BDU fixing system can also be called a BDU fixing structure assembly, which is a component that integrates the above-mentioned components with other auxiliary components (such as grounding terminals, cable connectors, etc.). Normally, the BDU is fixed to a specific position of the battery box or vehicle body through the BDU fixing system.

[0050] refer to Figure 6 — Fig.13 The BDU fixing system includes a BDU fixing tray 80, a fixing bracket 70 and a shock absorbing assembly. The shock absorbing assembly is arranged between the BDU fixing tray 80 and the fixing bracket 70. The BDU fixing tray 80 is used to install and fix the BDU. The upper end of the fixing bracket 70 is provided with an annular shell 71, and the annular shell 71 is used to accommodate and connect the shock absorbing assembly. Fig.13The lower end of the fixing bracket 70 is used to be connected to the ventral surface of the frame. The shock-absorbing assembly includes an upper shell 40, an upper stud 50, a shock-absorbing rubber 90, a washer and a lower stud 60. The shock-absorbing rubber 90 is arranged in the annular shell 71. The upper end of the shock-absorbing rubber 90 is vulcanized and connected to the upper shell 40 and the upper stud 50. The lower end of the shock-absorbing rubber 90 is vulcanized and connected to the lower stud 60 and the washer. The upper stud 50 is used to be fixedly connected to the BDU fixing tray 80 after being matched with its nut. The lower stud 60 is used to be fixedly connected to the fixing bracket 70 after being matched with its nut.

[0051] In a preferred embodiment, the BDU fixing tray 80 is an integrated structure, such as Figure 8 Specifically, the BDU fixed tray 80 is presented as an integral unit, and does not require connection processes such as splicing or welding to avoid affecting its installation accuracy due to the presence of welds.

[0052] Preferably, the BDU fixed tray 80 is composited with CFRT (continuous fiber reinforced thermoplastic unidirectional prepreg tape) and integrally hot-pressed. Compared with the existing truss assembly, it not only has a higher elastic modulus, but also does not require welding, thereby avoiding weld defects. One-time molding can well control dimensional accuracy and improve the integrity and consistency of the structure. In addition, CFRT composite materials have higher specific strength and specific modulus, and weigh only about 1 / 3 of the existing weight of 9.6 kg. The lightweight design can reduce the weight of the entire machine to improve maneuverability.

[0053] Preferably, the upper surface and / or lower surface of the BDU fixed tray 80 is covered with a cord layer, which can serve as a reinforcing layer and be well combined with the CFRT composite material matrix, thereby increasing the interlayer bonding strength and improving the interlayer shear strength and peeling resistance of the composite material. As a soft material, the cord layer can also absorb and disperse the impact load, thereby improving the toughness and impact resistance of the CFRT composite material under impact conditions. In addition, the cord layer can slow down the crack propagation rate, improve the fatigue performance of the CFRT composite material, and at the same time provide certain chemical corrosion resistance and aging resistance protection.

[0054] Preferably, after the BDU fixed tray 80 is hot-pressed, its cross-section includes at least one "J"-shaped structure 81, which is equivalent to forming a plurality of wave-like reinforcing ribs. This structure can greatly improve the bending stiffness of the entire cross-section, so that the BDU fixed tray 80 can withstand a larger bending load without obvious deformation. In addition, compared with the ordinary rectangular cross-section of the truss assembly in the prior art, the cross-section of the "J"-shaped structure 81 has a larger area moment of inertia, which means that it can provide higher torsional stiffness to effectively resist the effect of torsional loads; further, when the "J"-shaped structure 81 is subjected to an impact load, this wave-like structure is prone to controllable step-by-step destruction and absorbs more impact energy, thereby improving the impact resistance of the BDU fixed tray 80.

[0055] refer to Fig. 9 — Fig.12 In a preferred embodiment, the shock-absorbing rubber 90 in the shock-absorbing assembly is provided with a plurality of protrusions 91 and grooves 92 in the circumferential direction, and the protrusions 91 and the grooves 92 are both parallel to the axial extension of the shock-absorbing rubber 90, and the two are arranged at intervals. At this time, the cross-section of the shock-absorbing rubber 90 is roughly gear-shaped, and the plurality of grooves 92 are preferably evenly distributed along the circumference of the shock-absorbing rubber 90, and the outer diameter of the stroke defined by all the protrusions 91 matches the inner diameter of the annular shell 71, that is, the shock-absorbing rubber 90 and the annular shell 71 are transitionally matched, and the good transition fit between the two can transmit the load and avoid the radial gap between them to reduce the efficiency; and because the grooves 92 are evenly distributed throughout the circumference, when the upper stud 50 of the shock-absorbing assembly is subjected to a radial load in the 360° direction, the gear-shaped shock-absorbing rubber 90 creeps and fills the preset gap, which can effectively absorb the load.

[0056] Specifically, due to the presence of the protrusion 91 and the groove 92, space is provided for the shock-absorbing rubber 90 to deform radially. When subjected to a radial load, the protrusion 91 can deform in the direction of the groove 92, thereby greatly increasing the radial buffering deformation of the shock-absorbing rubber 90. Furthermore, when subjected to force, the stress of the traditional smooth cylindrical rubber is extremely unevenly concentrated in a local area, while the gear-shaped shock-absorbing rubber 90 enables the stress to be distributed to each protrusion 91, thereby avoiding stress concentration and causing premature damage to the rubber. In addition, the groove 92 provides a larger space for the deformation of the shock-absorbing rubber 90, and the uniform stress distribution enables the entire shock-absorbing rubber 90 to absorb more impact energy during the deformation process, thereby improving the shock-absorbing effect.

[0057] In a preferred embodiment, the lower end of the upper stud 50 extends into the middle of the shock-absorbing rubber 90, which, on the one hand, increases the effective contact area between the upper stud 50 and the shock-absorbing rubber 90, so that the radial load can be more evenly transmitted to the shock-absorbing rubber 90, and on the other hand, improves the restraint of the shock-absorbing rubber 90 during the stretching process, and enhances the supporting effect of the shock-absorbing rubber 90 on the upper stud 50. In addition, the risk of tilting of the upper stud 50 during the stretching process is reduced, ensuring that the load transfer is more effective and accurate; further, the effective support length between the upper stud 50 and the lower stud 60 is increased, the limit stroke between the upper stud 50 and the lower stud 60 is reduced, and the sensitivity and shock absorption efficiency of the shock-absorbing assembly under small stroke vibration are improved.

[0058] Preferably, an annular support element 51 is further provided on the outer periphery of the lower end of the upper stud 50. Fig.10 The annular support element 51 is arranged between the head of the upper stud 50 and the bottom surface of the upper shell 40. The length of the annular support element 51 is the same as the length of the upper stud 50 extending downward. The inner diameter of the annular support element 51 matches the outer diameter of the upper stud 50. More preferably, the annular support element 51 is an annular metal sleeve, such as an annular steel sleeve.

[0059] After adding the annular support element 51, the shock-absorbing participation of the shock-absorbing rubber 90 is increased when the upper stud 50 is subjected to radial load, so that the shock-absorbing deformation of the shock-absorbing rubber 90 will not be excessively concentrated in certain areas, and at the same time, the stress is dispersed to avoid excessive concentration of stress in local areas; since the annular support element 51 is arranged in the Z direction, it can effectively block the excessive displacement of the upper shell 40, realize effective limitation in the Z direction, and prevent the upper shell 40 from excessively stretching and displacing in the Z direction when subjected to impact load, thereby affecting the shock-absorbing performance.

[0060] Furthermore, since the annular shell 71 tightly wraps the shock-absorbing rubber 90, and the upper end of the shock-absorbing rubber 90 is vulcanized and connected to the upper shell 40, the annular shell 71 can effectively limit the upper shell 40 in the radial XY plane, thereby preventing the upper shell 40 from excessively sliding in the radial direction and reducing the shock-absorbing efficiency. Combined with the annular support element 51, the structure of the entire shock-absorbing assembly can achieve all-round limit of the upper shell 40 in the three directions of X, Y, and Z, so that the shock-absorbing assembly can maintain appropriate deformation space and shock-absorbing performance under the action of loads in all directions, thereby greatly improving the performance reliability of the entire shock-absorbing system.

[0061] Example 2

[0062] This embodiment provides a new energy commercial vehicle, including a battery pack and the BDU fixing system in the above embodiment 1. The technical features already recorded in the above embodiment 1 are naturally inherited in this embodiment and will not be repeated.

[0063] In this embodiment, the new energy commercial vehicles include pure electric trucks, pure electric buses, etc., which are not specifically limited here and can be freely selected by technicians in this field according to actual needs.

[0064] Although example embodiments have been described herein with reference to the accompanying drawings, it should be understood that the above example embodiments are merely exemplary and are not intended to limit the scope of the present application to this. Those of ordinary skill in the art may make various changes and modifications therein without departing from the scope and spirit of the present application. All these changes and modifications are intended to be included within the scope of the present application as required by the appended claims.

[0065] In the description provided herein, a large number of specific details are described. However, it is understood that the embodiments of the present application can be practiced without these specific details. In some instances, well-known methods, structures and techniques are not shown in detail so as not to obscure the understanding of this description.

[0066] Similarly, it should be understood that in order to streamline the present application and help understand one or more of the various utility model aspects, in the description of the exemplary embodiments of the present application, the various features of the present application are sometimes grouped together into a single embodiment, figure, or description thereof. However, the method of the present application should not be interpreted as reflecting the following intention: the claimed application requires more features than the features clearly stated in each claim. More specifically, as reflected in the corresponding claims, its utility model point is that the corresponding technical problem can be solved with less than all the features of a single disclosed embodiment. Therefore, the claims following the specific embodiment are hereby explicitly incorporated into the specific embodiment, wherein each claim itself serves as a separate embodiment of the present application.

[0067] It will be understood by those skilled in the art that, except for mutually exclusive features, all features disclosed in this specification (including the accompanying claims, abstracts and drawings) and all processes or units of any method or device disclosed in this specification may be combined in any combination. Unless otherwise expressly stated, each feature disclosed in this specification (including the accompanying claims, abstracts and drawings) may be replaced by an alternative feature that provides the same, equivalent or similar purpose.

Claims

1. A BDU fixing system, characterized in that: It includes a BDU fixing tray, a fixing bracket and a shock absorbing component arranged therebetween; The BDU fixing tray comprises an integrated structure formed by a composite of continuous fiber reinforced thermoplastic unidirectional prepreg tapes, and is used to install and fix the BDU; The upper end of the fixing bracket is provided with an annular housing for accommodating and connecting the shock absorbing assembly, and the lower end of the fixing bracket is used to be connected to the belly surface of the frame; The shock absorbing assembly includes an upper shell, an upper stud, a shock absorbing rubber, a gasket and a lower stud. The upper end of the shock absorbing rubber is vulcanized and connected to the upper shell and the upper stud, and the lower end of the shock absorbing rubber is vulcanized and connected to the lower stud and the gasket. The upper stud is used to be fixedly connected to the BDU fixed tray, and the lower stud is used to be fixedly connected to the fixed bracket.

2. The BDU fixing system according to claim 1, characterized in that: The shock-absorbing rubber is provided with a plurality of raised portions and groove portions in the circumferential direction. The raised portions and groove portions are both parallel to the axial extension of the shock-absorbing rubber and are arranged at intervals. The outer diameter defined by the raised portions matches the inner diameter of the annular shell, and the shock-absorbing rubber and the annular shell are transitionally matched.

3. The BDU fixing system according to claim 2, characterized in that: The cross section of the shock-absorbing rubber is gear-shaped, and a plurality of the grooves are evenly distributed along the circumference of the shock-absorbing rubber.

4. The BDU fixing system according to claim 3, characterized in that: The lower end of the upper stud extends into the middle of the shock-absorbing rubber, and an annular supporting element is arranged on the outer periphery of the lower end of the upper stud.

5. The BDU fixing system according to claim 4, characterized in that: The annular support element is arranged between the head of the upper stud and the bottom surface of the upper shell, the length of the annular support element is the same as the length of the upper stud extending downward, the inner diameter of the annular support element matches the outer diameter of the upper stud, and the annular support element is an annular metal sleeve.

6. The BDU fixing system according to claim 1, characterized in that: The BDU fixing tray is integrally formed by hot pressing.

7. The BDU fixing system according to claim 1, characterized in that: The upper surface and / or the lower surface of the BDU fixing tray is covered with a curtain layer.

8. The BDU fixing system according to claim 1, characterized in that: The cross section of the BDU fixing tray includes at least one "X"-shaped structure.

9. A battery pack, characterized in that: Comprising a BDU fixing system as described in any one of claims 1-8.

10. A new energy commercial vehicle, characterized in that: Comprising the battery pack as claimed in claim 9.

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