Power supply distributor

Abstract

The utility model relates to the technical field of power distribution structures, in particular to a power distributor applied to a new energy vehicle, which comprises a PDU (Power Distribution Unit) shell, a charging and discharging module, a conversion module, a detection module and a protection module, the shunt is sequentially connected with a charging high-voltage plug-in and a discharging high-voltage plug-in through a copper busbar The protection module comprises a main fuse, the main fuse is sequentially connected with the discharging relay and the charging relay, the protection module is arranged, the main fuse arranged by the protection module is used for protecting the charging and discharging module, and when overlarge high-voltage current is generated in the power supply distributor structure, the main fuse can be quickly fused to protect the charging and discharging module, so that the charging and discharging module is protected. Therefore, the power distributor structure can be protected during working.

Description

Technical Field

[0001] The utility model relates to the technical field of power distribution structures, in particular to a power distributor structure for a vehicle. Background Art

[0002] The power distributor, also known as the high-voltage power distribution unit (PDU), is a key component in new energy vehicles. It is mainly used for intelligent distribution current management, enabling drivers and passengers to power or charge multiple electronic devices at the same time, such as mobile phones, tablets, GPS navigation devices, dashboard cameras and other portable devices.

[0003] The power distributor is generally composed of relays, fuses, discharge resistors, pre-charge resistors, pre-charge relays, distribution sockets and voltage sampling lines at various points. Currently, there are several PDU solutions:

[0004] One is to install the relay and resistor on the sheet metal, install the fuse on the fuse base or customized plastic parts, and connect the relay, fuse, resistor and distribution socket with copper bus and power cable;

[0005] One is to design a printed circuit board (PCB), design the relay, fuse, discharge resistor, pre-charge relay, and voltage sampling lines at each point on the PCB according to the circuit design, and connect the circuits through the copper cladding on the PCB. The pre-charge resistor is installed on the sheet metal, connected to the PCB through a wire, and connected to the power distribution socket through a wire.

[0006] However, no matter which of the above solutions is used, there is a risk of electric shock from high voltage current.

[0007] In the utility model patent with application number 201720567008.5, a PDU for electric vehicles with a high-voltage interlocking structure for protection against electric shock is specifically disclosed, including a PDU box body and a box cover. A micro switch is fixed on the inner wall of the PDU box body, and the micro switch is located at the contact point between the box cover and the box body. A battery manager is arranged in the PDU box body, and a plug-in interlocking interface connected to the interlocking signal input end of the battery manager and a control relay connected to the control signal output end of the battery manager is also provided. The micro switch is connected to the detection signal input end of the vehicle controller, and the control signal end of the vehicle controller is connected to the control signal receiving end of the battery manager.

[0008] However, the above technical solution only ensures safety during maintenance, but does not guarantee the safety of the PDU during normal operation. Utility Model Content

[0009] In view of the above problems, the utility model provides a power distributor, which protects the charging and discharging module by setting a protection module and utilizing the main fuse set in the protection module. When excessive high voltage current is generated in the power distributor structure, the main fuse will blow quickly to protect the charging and discharging module, thereby achieving the goal of protecting the power distributor structure during operation.

[0010] In order to achieve the above purpose, the utility model provides the following technical solutions:

[0011] A power distributor includes a PDU housing and further includes:

[0012] Charging and discharging module, conversion module, detection module and protection module;

[0013] The charging and discharging module includes a charging high-voltage plug-in, a charging relay, a discharging relay and a discharging high-voltage plug-in. The charging high-voltage plug-in and the discharging high-voltage plug-in are both embedded in the PDU housing. The charging relay and the discharging relay are both installed in the PDU housing. The charging high-voltage plug-in is connected to the charging relay, and the discharging relay is connected to the discharging high-voltage plug-in.

[0014] The conversion module includes a DC-DC converter and a BMS integrated machine installed in the PDU housing, the DC-DC converter is arranged above the BMS integrated machine, and the DC-DC converter and the BMS integrated machine are respectively connected to the charging and discharging module;

[0015] The detection module includes a shunt and a busbar installed in the PDU housing, and the shunt is connected to the charging high-voltage plug-in and the discharging high-voltage plug-in in sequence through the busbar;

[0016] The protection module includes a main fuse, and the main fuse is connected to the discharge relay and the charging relay in sequence.

[0017] As an improvement, the charging and discharging module further includes a charging communication plug-in arranged side by side with the charging high-voltage plug-in.

[0018] As an improvement, the charging and discharging module further includes a discharge communication plug-in arranged side by side with the discharge high voltage plug-in.

[0019] As an improvement, the protection module further includes a pre-charging resistor and a pre-charging relay;

[0020] The pre-charging resistor is connected to the charging and discharging module;

[0021] The pre-charging relay is connected to the pre-charging resistor.

[0022] As an improvement, the protection module further includes a positive electrode heating relay, a heating fuse and a negative electrode heating relay, and the positive electrode heating relay is connected to the positive electrode line of the charging and discharging module;

[0023] The heating fuse is connected to the positive electrode heating relay;

[0024] The negative electrode heating relay is connected to the negative electrode line of the charging and discharging module.

[0025] As an improvement, an LED indicator light is installed on the PDU housing.

[0026] As an improvement, an antenna is installed on the PDU housing.

[0027] As an improvement, a buzzer is installed on the PDU housing.

[0028] The beneficial effects of the utility model are:

[0029] The utility model provides a protection module and utilizes a main fuse provided in the protection module to protect the charging and discharging module. When an excessively high voltage current is generated in the power distributor structure, the main fuse will quickly blow to protect the charging and discharging module, thereby achieving protection of the power distributor structure during operation.

[0030] The utility model sets a detection module and utilizes the shunt in the detection module to perform real-time detection on the current currently flowing through the charging and discharging module. When the current flowing through the charging and discharging module is abnormally large, real-time feedback can be given to issue an alarm.

[0031] In summary, the utility model has the advantages of good protection, high integration, safety and reliability, and is particularly suitable for the technical field of vehicle PDU structure. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 This is a schematic diagram of the explosion structure of the utility model;

[0033] Figure 2 It is a schematic diagram of the structure of the utility model from top view. DETAILED DESCRIPTION

[0034] The following will be combined with the drawings in the embodiments of the utility model to clearly and completely describe the technical solutions in the embodiments of the utility model. Obviously, the described embodiments are only part of the embodiments of the utility model, not all of the embodiments. Based on the embodiments in 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.

[0035] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present invention.

[0036] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the features. In the description of the present utility model, the meaning of "plurality" is two or more, unless otherwise clearly and specifically defined.

[0037] Embodiment 1:

[0038] like Figure 1 to Figure 2 As shown, a power distributor includes a PDU housing 1 and further includes:

[0039] Charging and discharging module 2, conversion module 3, detection module 4 and protection module 5;

[0040] The charging and discharging module 2 includes a charging high-voltage plug-in 21, a charging relay 22, a discharging relay 23 and a discharging high-voltage plug-in 24. The charging high-voltage plug-in 21 and the discharging high-voltage plug-in 24 are both embedded in the PDU housing 1. The charging relay 22 and the discharging relay 23 are both installed in the PDU housing 1. The charging high-voltage plug-in 21 is connected to the charging relay 22, and the discharging relay 23 is connected to the discharging high-voltage plug-in 24.

[0041] The main function of the charging high-voltage plug-in 21 in the PDU is to manage and control the access and distribution of high-voltage power from the external charging source. The charging high-voltage plug-in provides a safe interface for transmitting power from the external charging pile to the high-voltage system of the electric vehicle. This interface ensures that the high voltage and high current during the charging process can be transmitted safely and reliably.

[0042] Correspondingly, the role of the discharge high-voltage plug-in 24 in the PDU is just opposite to that of the charge high-voltage plug-in 21 , and the discharge high-voltage plug-in provides a safe interface for outputting electrical energy to the outside.

[0043] The main function of the charging relay 22 in the PDU is to connect and disconnect the charging circuit between the battery and the external charging source. In this way, it can start or stop the charging process when necessary, thereby controlling the flow of electricity. During the power-on (connecting the circuit) and power-off (disconnecting the circuit), the relay can ensure the safety of this process.

[0044] Accordingly, the function of the discharge relay 23 in the PDU is similar to that of the charging relay 22, except that the discharge relay 23 is responsible for connecting and disconnecting the charging circuit between the battery and the external electrical appliance.

[0045] The conversion module 3 includes a DC-DC converter 31 and a BMS integrated machine 32 installed in the PDU housing 1, the DC-DC converter 31 is arranged above the BMS integrated machine 32, and the DC-DC converter 31 and the BMS integrated machine 32 are respectively connected to the charging and discharging module 2;

[0046] The role of the DC-DC converter 31 in the PDU is to convert one DC voltage level to another DC voltage level. In an electric vehicle, this means converting from the high-voltage battery pack to adapt to the different voltage levels required by different components inside the vehicle, such as powering low-voltage electronic devices.

[0047] The role of the BMS 32 in the PDU is to monitor and manage key parameters of the battery unit or group, such as voltage, current and temperature, to prevent overcharging, over-discharging, over-temperature or other conditions that may cause battery damage. By ensuring that the battery operates within a safe range, the BMS helps to extend battery life and avoid potential safety issues.

[0048] The detection module 4 includes a shunt 41 and a busbar 42 installed in the PDU housing 1, and the shunt 41 is connected to the charging high-voltage plug-in 21 and the discharging high-voltage plug-in 24 in sequence through the busbar 42;

[0049] The shunt 41 can be used in a power system to evenly distribute current, ensuring that power flows safely along a predetermined path. In complex power systems, especially where power needs to be distributed to multiple loads, the shunt helps to effectively distribute current to ensure that each component is adequately and evenly powered. At the same time, another key function is to measure the current passing through it. The shunt measures the current in the main circuit by providing a path with a known small resistance value so that a small amount of current flows through the shunt. In this way, large currents can be accurately measured without affecting the normal operation of the main circuit.

[0050] The protection module 5 includes a main fuse 51, and the main fuse 51 is connected to the discharge relay 23 and the charging relay 22 in sequence;

[0051] The main function of the main fuse 51 is to provide overcurrent protection. When the current exceeds the maximum carrying capacity of the fuse, the fuse will automatically disconnect the circuit to prevent overheating of the wire, fire or damage to the equipment. This protection is passive and can be automatically triggered without external control.

[0052] In addition, the charging and discharging module 2 further includes a charging communication plug-in 25 arranged side by side with the charging high-voltage plug-in 21 .

[0053] Furthermore, the charging and discharging module 2 also includes a discharge communication plug-in 26 arranged side by side with the discharge high-voltage plug-in 24 .

[0054] The charging communication plug-in 25 can realize the control and management of the charging process, including starting and stopping charging, adjusting the charging power, etc. This control can be optimized based on real-time demand, grid conditions or charging strategies, and the charging communication plug-in 25 supports two-way data exchange between the power source and the charging device. This includes the transmission of status information (such as battery charging status, fault information), metering data (charge amount, power) and control instructions.

[0055] The discharge communication plug-in 26 can perform precise discharge control on the energy storage system connected to the PDU, including adjustment of the discharge rate, time and amount to adapt to specific energy needs or optimize energy efficiency.

[0056] The Discharge Communication Plug-in 26 allows the PDU to communicate with a battery management system (BMS) or other energy storage system to achieve optimized management of energy storage resources. This may involve dynamic energy allocation based on real-time grid demand, electricity prices or renewable energy availability.

[0057] Embodiment 2:

[0058] With reference to Example 1, the difference between Example 2 and Example 1 of the utility model is described as follows:

[0059] like Figure 1 As shown, the protection module 5 also includes a pre-charging resistor 52 and a pre-charging relay 53;

[0060] The pre-charging resistor 52 is connected to the charging and discharging module 2;

[0061] The pre-charging relay 53 is connected to the pre-charging resistor 52 .

[0062] The role of the pre-charge resistor in the power distribution unit (PDU) is to mitigate the current surge when the system is first powered on. If this surge is not controlled, it may cause damage to the electronic equipment, circuits and connected devices in the PDU, because when a large capacitor or high-energy battery pack is directly connected, the initial current may far exceed the normal operating current of the equipment.

[0063] When the PDU is first connected to the power supply or battery pack, the pre-charge resistor will limit the initial current flowing through the circuit to prevent the circuit from short-circuiting, damaging components or generating electric sparks due to sudden large current.

[0064] The function of the pre-charge relay 53 is that when the power system is first powered on or during the restart process, the pre-charge relay is first turned on to route the current to the capacitor or battery pack through the pre-charge resistor. This can limit the initial current and prevent damage to the circuit or sensitive components.

[0065] Embodiment 3:

[0066] With reference to Example 1, the difference between Example 3 and Example 1 of the utility model is described as follows:

[0067] like Figure 1 As shown, the protection module 5 further includes a positive electrode heating relay 54, a heating fuse 55 and a negative electrode heating relay 56, and the positive electrode heating relay 54 is connected to the positive electrode line of the charging and discharging module 2;

[0068] The heating fuse 55 is connected to the positive electrode heating relay 54;

[0069] The negative electrode heating relay 56 is connected to the negative electrode line of the charging and discharging module 2 .

[0070] The positive pole heating relay 54 can control the on and off of the heating element to heat the key parts of the PDU or connected equipment, such as the battery pack, to keep it working normally or improve its performance at low temperatures.

[0071] The function of the negative electrode heating relay 56 is similar to that of the positive electrode heating relay 54, and its main purpose is to control the heating element associated with the negative electrode to maintain the electronic device or battery system at a suitable operating temperature, especially in a cold environment.

[0072] The function of the heating fuse 55 in the PDU is to provide circuit overload protection and protect the positive heating relay 54 and the negative heating relay 56. When the current passing through the fuse exceeds its design limit, the fuse will melt (disconnect), thereby cutting off the circuit and preventing excessive current from damaging the circuit or equipment.

[0073] Embodiment 4:

[0074] With reference to Example 1, the difference between Example 4 and Example 1 of the utility model is described as follows:

[0075] like Figure 1 As shown, an LED indicator light 6 is installed on the PDU housing 1 , and the LED indicator light 6 is connected to the BMS integrated machine. The BMS integrated machine displays various parameters through the LED indicator light 6 .

[0076] Furthermore, a buzzer 8 is installed on the PDU housing 1, and the buzzer 8 is connected to the BMS all-in-one machine. When a fault occurs in the PDU, the buzzer 8 sounds.

[0077] Embodiment 5:

[0078] With reference to Example 1, the difference between Example 5 and Example 1 of the utility model is described as follows:

[0079] like Figure 1 As shown, an antenna 7 is installed on the PDU housing 1, and the antenna 7 is connected to the BMS integrated machine.

[0080] Antenna 7 is used to receive and / or send wireless signals, allowing the PDU to communicate with an external system or network. This may be used to remotely monitor the status of the PDU, such as current load, temperature, etc., or to perform remote control operations.

[0081] Additionally, through wireless communication, the antenna can support remote management of the PDU, allowing system administrators to remotely configure PDU settings, switch output ports, or monitor energy consumption.

[0082] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A power distributor, comprising a PDU housing (1), characterized in that: Also includes: A charging and discharging module (2), a conversion module (3), a detection module (4) and a protection module (5); The charging and discharging module (2) comprises a charging high-voltage plug-in (21), a charging relay (22), a discharging relay (23) and a discharging high-voltage plug-in (24); the charging high-voltage plug-in (21) and the discharging high-voltage plug-in (24) are both embedded in the PDU housing (1); the charging relay (22) and the discharging relay (23) are both installed in the PDU housing (1); the charging high-voltage plug-in (21) is connected to the charging relay (22), and the discharging relay (23) is connected to the discharging high-voltage plug-in (24); The conversion module (3) comprises a DC-DC converter (31) and a BMS integrated machine (32) installed in the PDU housing (1); the DC-DC converter (31) is arranged above the BMS integrated machine (32); and the DC-DC converter (31) and the BMS integrated machine (32) are respectively connected to the charging and discharging module (2); The detection module (4) comprises a shunt (41) and a busbar (42) installed in the PDU housing (1); the shunt (41) is connected to the charging high-voltage plug-in (21) and the discharging high-voltage plug-in (24) in sequence through the busbar (42); The protection module (5) comprises a main fuse (51), and the main fuse (51) is connected to the discharge relay (23) and the charging relay (22) in sequence.

2. A power distributor according to claim 1, characterized in that: The charging and discharging module (2) further comprises a charging communication plug-in (25) arranged side by side with the charging high-voltage plug-in (21).

3. A power distributor according to claim 1, characterized in that: The charging and discharging module (2) further comprises a discharge communication plug-in (26) arranged side by side with the discharge high-voltage plug-in (24).

4. A power distributor according to claim 1, characterized in that: The protection module (5) further comprises a pre-charging resistor (52) and a pre-charging relay (53); The pre-charging resistor (52) is connected to the charging and discharging module (2); The pre-charging relay (53) is connected to the pre-charging resistor (52).

5. A power distributor according to claim 1, characterized in that: The protection module (5) further comprises a positive electrode heating relay (54), a heating fuse (55) and a negative electrode heating relay (56); the positive electrode heating relay (54) is connected to the positive electrode line of the charging and discharging module (2); The heating fuse (55) is connected to the positive electrode heating relay (54); The negative electrode heating relay (56) is connected to the negative electrode line of the charging and discharging module (2).

6. A power distributor according to claim 1, characterized in that: An LED indicator light (6) is installed on the PDU housing (1).

7. A power distributor according to claim 4, characterized in that: An antenna (7) is installed on the PDU housing (1).

8. A power distributor according to claim 1, characterized in that: A buzzer (8) is installed on the PDU housing (1).

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