Zero wire harness high-voltage power distribution unit

Abstract

The utility model relates to a zero wire harness high-voltage power distribution unit, which comprises a main positive circuit, a pre-charging circuit, a fast charging circuit, a heating circuit, a main negative circuit, a high-voltage acquisition plug connector and a low-voltage control plug connector, the main positive circuit, the pre-charging circuit, the fast charging circuit and the heating circuit are connected in parallel and then are connected to the positive electrode of a battery, and the main negative circuit is connected to the negative electrode of the battery; the low-voltage control plug connector is respectively connected with low-voltage control ends of electrical parts in the main positive circuit, the pre-charging circuit, the quick charging circuit and the heating circuit; the high-voltage collection plug connector collects electrical parameters of electrical parts in the main positive circuit, the pre-charging circuit, the quick charging circuit and the heating circuit. According to the utility model, a wiring harness structure used in a traditional electrical architecture is canceled, and most of components in the main circuit, the pre-charging circuit, the heating circuit, the quick charging circuit, the high-voltage acquisition circuit and the low-voltage control circuit are all integrated on the PCB, so that high integration of the product is realized, the cost of the product is reduced, and the effects of reducing cost and increasing efficiency are achieved.

Description

Technical Field

[0001] The utility model relates to the technical field of new energy vehicles, and in particular to a zero-wire harness high-voltage power distribution unit. Background Art

[0002] BDU (Battery Disconnect Unit) is a type of power distribution box designed for the inside of the battery pack. According to the location of the BDU in the battery pack, it can be divided into the type installed inside the battery box and the type installed outside the box. The internal control circuit, pre-charging circuit, heating circuit, high-voltage acquisition circuit, etc. of the traditional BDU circuit are all connected by wires. Although wires have the advantages of low cost and no technical threshold, this method requires the addition of wiring terminals, wire clamps to fix the wiring harness, and other structures. The wiring harness itself will be messy and occupy a large space, which will cause problems such as complex processes, high failure rates, and cumbersome production and assembly procedures. In addition, the wires and terminals are prone to loosening and falling off, resulting in high after-sales service costs. Utility Model Content

[0003] The embodiment of the utility model provides a zero-wire harness high-voltage power distribution unit to solve the problems of high failure rate and low integration degree caused by wire harness connection in the prior art.

[0004] In order to achieve the above purpose, the embodiment of the utility model provides the following technical solutions:

[0005] A zero-wire harness high-voltage power distribution unit comprises a main positive circuit, a pre-charging circuit, a fast-charging circuit, a heating circuit, a main negative circuit, a high-voltage acquisition connector and a low-voltage control connector. The main positive circuit, the pre-charging circuit, the fast-charging circuit and the heating circuit are connected in parallel and then connected to the positive electrode of the battery, and the main negative circuit is connected to the negative electrode of the battery; the low-voltage control connector is respectively connected to the low-voltage control ends of the electrical components in the main positive circuit, the pre-charging circuit, the fast-charging circuit and the heating circuit; the high-voltage acquisition connector respectively collects electrical parameters of the electrical components in the main positive circuit, the pre-charging circuit, the fast-charging circuit and the heating circuit.

[0006] Furthermore, the main positive circuit, pre-charging circuit, fast charging circuit and heating circuit are connected in parallel and then connected to a fuse, and the fuse is connected to the positive electrode of the battery.

[0007] Furthermore, the pre-charging circuit is provided with a pre-charging relay and a pre-charging resistor which are connected in series with each other.

[0008] Furthermore, the heating circuit is provided with a heating relay and a heating fuse which are connected in series with each other.

[0009] Furthermore, the main negative circuit is provided with a main negative relay and a current sensor connected in series with each other.

[0010] Furthermore, the main positive circuit, pre-charging circuit, fast charging circuit, heating circuit, and main negative circuit are all integrated on a PCB board, and the PCB board is fixed in the shell; for the electrical components in each circuit, if there is no relative distance between the electrical contacts of the electrical components and the corresponding electrical contacts on the PCB board, the shell is provided with a receiving groove for inserting the electrical components; if there is a relative distance between the electrical contacts of the electrical components and the corresponding electrical contacts on the PCB board, the shell is provided with a mounting position for installing the electrical component, and a copper busbar connecting the mounting position and the corresponding electrical contacts on the PCB is provided in the shell.

[0011] Furthermore, a plurality of isolation boxes are provided in the shell, and a first copper bar is provided on the isolation box, one end of the first copper bar is fixedly connected to the electrical contact on the top of the isolation box, and the other end of the first copper bar is fixedly connected to the electrical contact on the PCB board.

[0012] Furthermore, the isolation box is provided with a second copper bar connected to the first copper bar, and the second copper bar is used to connect the first copper bar and electrical contacts of the electrical device integrated on the PCB board.

[0013] Furthermore, the shell is provided with grooves for accommodating various electrical components in the main positive circuit, pre-charging circuit, fast charging circuit, heating circuit, and main negative circuit.

[0014] The utility model embodiment has the following advantages:

[0015] The utility model discloses a zero-wiring harness high-voltage power distribution unit which cancels the wiring harness structure used in the traditional electrical architecture, and connects the main circuit, pre-charging circuit, heating circuit and fast-charging circuit in parallel to simplify the circuit structure; moreover, most of the components in the main circuit, pre-charging circuit, heating circuit, fast-charging circuit, high-voltage acquisition circuit and low-voltage control circuit are integrated on the PCB board, and the non-integrated electrical components that cannot be integrated are fixed by the shell according to the external structure and the height and spatial position relationship between the various electrical components, so as to realize the high integration of the product, increase the degree of automation after integration, and improve the production efficiency, thereby reducing the cost of the product and achieving the effect of reducing cost and increasing efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] In order to more clearly illustrate the implementation of the utility model or the technical solution in the prior art, the following is a brief introduction to the drawings required for the implementation or the prior art description. Obviously, the drawings in the following description are only exemplary, and for ordinary technicians in this field, other implementation drawings can be derived from the provided drawings without creative work.

[0017] The structures, proportions, sizes, etc. illustrated in this specification are only used to match the contents disclosed in the specification so as to facilitate understanding and reading by persons familiar with the technology. They are not used to limit the conditions under which the present invention can be implemented, and therefore have no substantial technical significance. Any structural modification, change in proportion or adjustment of size shall still fall within the scope of the technical contents disclosed in the present invention without affecting the effects and purposes that can be achieved by the present invention.

[0018] Figure 1 A circuit diagram of a zero-wire harness high-voltage power distribution unit provided by an embodiment of the utility model, wherein the thick lines are the main positive circuit and the main negative circuit, the thin solid lines are the low-voltage control circuit, and the dot-dash lines are the high-voltage control circuit;

[0019] Figure 2 An exploded diagram of a zero-wire harness high-voltage power distribution unit provided in an embodiment of the utility model;

[0020] Figure 3 A PCB board structure diagram of a zero-wire harness high-voltage power distribution unit provided in an embodiment of the utility model;

[0021] Figure 4 A product assembly diagram of a zero-wire high-voltage power distribution unit provided in an embodiment of the utility model.

[0022] In the figure:

[0023] 1. Main positive circuit; 2. Pre-charging circuit; 3. Fast charging circuit; 4. Heating circuit; 5. Main negative circuit; 6. High-voltage acquisition connector; 7. Low-voltage control connector; 8. Fuse; 9. Main positive relay; 10. Pre-charging relay; 11. Pre-charging resistor; 12. Fast charging relay; 13. Heating relay; 14. Heating fuse; 15. Main negative relay; 16. Current sensor; 17. PCB board; 18. Shell; 19. First copper busbar; 20. Second copper busbar; 21. First isolation box; 22. Second isolation box. DETAILED DESCRIPTION

[0024] The following is a specific embodiment of the present invention. People familiar with the technology can easily understand the other advantages and functions of the present invention from the contents disclosed in this specification. Obviously, the described embodiment is a part of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0025] like Figure 1As shown, a zero-wire harness high-voltage power distribution unit includes a main positive circuit 1, a pre-charging circuit 2, a fast charging circuit 3, a heating circuit 4, a main negative circuit 5, a high-voltage acquisition connector 6, and a low-voltage control connector 7. The main positive circuit 1, the pre-charging circuit 2, the fast charging circuit 3, and the heating circuit 4 are connected in parallel and then connected to the positive electrode of the battery. The main positive circuit 1, the pre-charging circuit 2, the fast charging circuit 3, and the heating circuit 4 are connected in parallel to a fuse 8, and the fuse 8 is connected to the positive electrode of the battery, so that a fuse 8 can simultaneously meet the fusing functions of the main positive circuit 1, pre-charging, fast charging, heating, and other circuits, thereby realizing circuit integration.

[0026] Specifically, the main positive circuit 1 is provided with a main positive relay 9; the pre-charging circuit 2 is provided with a pre-charging relay 10 and a pre-charging resistor 11 which are connected in series to each other, and the pre-charging relay 10 and the pre-charging resistor 11 are connected in series and then connected in parallel to the main positive relay 9; the fast charging circuit 3 is provided with a fast charging relay 12, and the fast charging relay 12 is connected in parallel to the main positive relay 9; the heating circuit 4 is provided with a heating relay 13 and a heating fuse 14 which are connected in series to each other, and the heating relay 13 and the heating fuse 14 are connected in series and then connected in parallel to the main positive relay 9.

[0027] The main negative circuit 5 is connected to the negative electrode of the battery. Specifically, the main negative circuit 5 is provided with a main negative relay 15 and a current sensor 16 connected in series with each other, and the current sensor 16 is connected to the negative electrode of the battery.

[0028] The low-voltage control connector 7 is respectively connected to the low-voltage control ends of the electrical components in the main positive circuit 1, the pre-charging circuit 2, the fast charging circuit 3, and the heating circuit 4, that is, it is respectively connected to the low-voltage control ends of the main positive relay 9, the pre-charging relay 10, the fast charging relay 12, the heating relay 13, and the main negative relay 15.

[0029] The high-voltage collection connector 6 collects electrical parameters of electrical components in the main positive circuit 1, pre-charging circuit 2, fast charging circuit 3, and heating circuit 4 respectively. Since the main positive circuit 1, pre-charging circuit 2, fast charging circuit 3, and heating circuit 4 are all connected in parallel, one collection point is set at the parallel point of these four circuits, and another collection point is set on the other side of each relay, thereby realizing an integrated collection circuit in which 5 collection points collect 4 relays, thereby realizing circuit integration.

[0030] This technology integrates various electrical components such as relays, pre-charging resistors 11, fuses 8, etc. on the circuit board, and then integrates the high-voltage signal acquisition circuit, low-voltage control circuit and most of the electrical components on the PCB board 17 through reasonable circuit board layout design. The structure between various electrical components is compact. This method replaces the traditional wire connection, truly realizes the zero wire harness integrated structure, and greatly reduces the volume of the entire product. Specifically, the main positive circuit 1, pre-charging circuit 2, fast charging circuit 3, heating circuit 4, and main negative circuit 5 are all integrated on the PCB board 17, and the PCB board 17 is fixed in the housing 18; for the electrical components in each circuit, if there is no relative distance between the electrical contacts of the electrical components and the corresponding electrical contacts on the PCB board 17, the housing 18 is provided with a receiving groove for inserting the electrical components; if there is a relative distance between the electrical contacts of the electrical components and the corresponding electrical contacts on the PCB board 17, the housing 18 is provided with a mounting position for installing the electrical components, and the housing 18 is provided with a copper bar connecting the mounting position and the corresponding electrical contacts on the PCB.

[0031] like Figure 2 As shown, the main positive relay 9, fuse 8, pre-charge relay 10, pre-charge resistor 11, fast charge relay 12, main negative relay 15, high voltage collection connector 6 and low voltage control connector 7 are integrated onto the PCB board 17 in combination with the aforementioned circuit structure.

[0032] Since the shell 18 has a certain height and is limited by the external structure of each electrical component, not all electrical components can be integrated into the PCB board 17, so copper bars are needed for connection. The shell 18 is provided with a plurality of isolation boxes for guiding the direction of the copper bars. The isolation box is provided with a first copper bar 19, one end of the first copper bar 19 is fixedly connected to the electrical contact on the top of the isolation box, and the other end of the first copper bar 19 is fixedly connected to the electrical contact on the PCB board 17. The first copper bar 19 is used to guide the electrical contacts on the PCB board 17 to the top surface of the shell 18, thereby reducing the difficulty of the installation process to a minimum, which is convenient for later processing and can even realize automated installation.

[0033] If the electrical components on the PCB board 17 need to be connected to the first copper bar 19, the isolation box is provided with a second copper bar 20 connected to the first copper bar 19. The second copper bar 20 is used to connect the first copper bar 19 with the electrical contacts of the electrical components integrated on the PCB board 17. This structure allows the copper bar to be bent at most once, greatly reducing the complexity of the copper bar, simplifying the product structure, facilitating the simplification of the heat dissipation structure, and achieving high integration of the product.

[0034] like Figure 2As shown, four first isolation boxes 21 are provided on the upper side of the shell 18, and three first isolation boxes 21 are provided on the lower side. For the four first isolation boxes 21 on the upper side, from left to right, the first two first isolation boxes 21 are used to support the first copper bars 19 of the electrical contacts on both sides of the current sensor 16, and the right electrical contacts of the current sensor 16 are connected to the copper bar of the main negative relay 15; the last two first isolation boxes 21 are used to support the first copper bars 19 at both ends of the heating relay 13, and one of the first copper bars 19 is also connected to the parallel copper bars of the main positive relay 9 and the pre-charge relay 10. For the three first isolation boxes 21 on the lower side, they are used to connect the negative ends of the main negative relay 15, the pre-charge relay 10, and the main positive relay 9 in turn from left to right. In order to make the heights of each electrical component equivalent, a second isolation box 22 lower than the first isolation box 21 is also provided on the shell 18, as shown Figure 2 In the embodiment, two second isolation boxes 22 are provided on the right side of the housing 18 for mounting the fuse 8 .

[0035] The housing 18 is provided with receiving grooves for receiving various electrical components on the main positive circuit 1, the pre-charging circuit 2, the fast charging circuit 3, the heating circuit 4, and the main negative circuit 5. The receiving grooves are used to expose the main positive relay 9, the fuse 8, the pre-charging relay 10, the pre-charging resistor 11, the fast charging relay 12, the main negative relay 15, the high-voltage collection connector 6, and the low-voltage control connector 7, so as to facilitate the heat dissipation of various electrical components.

[0036] Although the utility model has been described in detail above with general descriptions and specific embodiments, it is obvious to those skilled in the art that some modifications or improvements can be made to the utility model. Therefore, these modifications or improvements made without departing from the spirit of the utility model are within the scope of protection claimed by the utility model.

Claims

1. A zero-wire high-voltage distribution unit, characterized in that: It includes a main positive circuit, a pre-charging circuit, a fast charging circuit, a heating circuit, a main negative circuit, a high-voltage collection connector and a low-voltage control connector. The main positive circuit, the pre-charging circuit, the fast charging circuit and the heating circuit are connected in parallel and then connected to the positive electrode of the battery. The main negative circuit is connected to the negative electrode of the battery. The low-voltage control connector is respectively connected to the low-voltage control terminals of the electrical components in the main positive circuit, the pre-charging circuit, the fast charging circuit, and the heating circuit; The high-voltage acquisition connector respectively acquires electrical parameters of electrical components in the main positive circuit, the pre-charging circuit, the fast charging circuit, and the heating circuit.

2. A zero-wire high-voltage power distribution unit according to claim 1, characterized in that: The main positive circuit, pre-charging circuit, fast charging circuit and heating circuit are connected in parallel and then connected to a fuse, and the fuse is connected to the positive electrode of the battery.

3. A zero-wire high-voltage power distribution unit according to claim 1, characterized in that: The pre-charging circuit is provided with a pre-charging relay and a pre-charging resistor which are connected in series with each other.

4. A zero-wire high-voltage power distribution unit according to claim 1, characterized in that: The heating circuit is provided with a heating relay and a heating fuse which are connected in series with each other.

5. A zero-wire high-voltage power distribution unit according to claim 1, characterized in that: The main negative circuit is provided with a main negative relay and a current sensor which are connected in series with each other.

6. A zero-wire high-voltage distribution unit according to any one of claims 1 to 5, characterized in that: The main positive circuit, pre-charging circuit, fast charging circuit, heating circuit, and main negative circuit are all integrated on a PCB board, and the PCB board is fixed in the housing; For the electrical components in each circuit, if there is no relative distance between the electrical contacts of the electrical components and the corresponding electrical contacts on the PCB, a receiving groove for inserting the electrical components is provided on the housing; If there is a relative distance between the electrical contacts of the electrical component and the corresponding electrical contacts on the PCB, a mounting position for mounting the electrical component is provided on the housing, and a copper busbar connecting the mounting position and the corresponding electrical contacts on the PCB is provided inside the housing.

7. A zero-wire high-voltage power distribution unit according to claim 6, characterized in that: A plurality of isolation boxes are arranged in the shell, and a first copper bar is arranged on the isolation box. One end of the first copper bar is fixedly connected to the electrical contact on the top of the isolation box, and the other end of the first copper bar is fixedly connected to the electrical contact on the PCB board.

8. A zero-wire high-voltage power distribution unit according to claim 7, characterized in that: The isolation box is provided with a second copper bar connected to the first copper bar, and the second copper bar is used to connect the first copper bar and the electrical contacts of the electrical components integrated on the PCB board.

9. A zero-wire high-voltage power distribution unit according to claim 6, characterized in that: The shell is provided with grooves for accommodating various electrical components on the main positive circuit, the pre-charging circuit, the fast charging circuit, the heating circuit, and the main negative circuit.

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