Controller device of vehicle and new energy commercial vehicle

Abstract

The utility model discloses a controller device of a vehicle and a new energy commercial vehicle. The controller device comprises a shell and a controller body. The controller body comprises a five-in-one controller and other functional units; the other functional units comprise an insulation detection unit and a battery high-voltage power distribution unit; the battery high-voltage power distribution unit is provided with a charging and power distribution branch; the five-in-one controller is integrated with the insulation detection unit and the battery high-voltage power distribution unit; and / or, in the battery high-voltage power distribution unit, the number of the charging and power distribution branches is at least two; the at least two charging and distribution branches are connected in parallel; under the condition that the five-in-one controller, the battery high-voltage power distribution unit and the insulation detection unit are integrally arranged and the number of the charging and power distribution branches is at least two, the double-branch six-in-one integrated controller is obtained. According to the scheme, the five-in-one controller, the insulation detection unit and the high-voltage distribution box are integrated, and a double-branch double-charging distribution scheme is adopted, so that the integration level is improved, the development cost is reduced, and the charging function is realized.

Description

Technical Field

[0001] The utility model belongs to the technical field of new energy commercial vehicles, and specifically relates to a vehicle controller device and a new energy commercial vehicle having the vehicle controller device, and in particular to a dual-branch six-in-one controller of a new energy commercial vehicle and a new energy commercial vehicle having the dual-branch six-in-one controller of the new energy commercial vehicle. Background Art

[0002] New energy commercial vehicles have become a green transportation choice in the field of urban logistics and public transportation. New energy commercial vehicles mainly include: buses, passenger cars, trucks and other models. The control of the power system of new energy commercial vehicles generally adopts the form of "battery high-voltage distribution box + five-in-one controller", but the battery high-voltage distribution box and the five-in-one controller each occupy a relatively large space and have high assembly costs. At least there are problems of low integration and high development costs.

[0003] The above contents are only used to assist in understanding the technical solution of the present utility model and do not constitute an admission that the above contents are prior art. Utility Model Content

[0004] The purpose of the utility model is to provide a vehicle controller device and a new energy commercial vehicle to solve the problem that the control of the power system of the new energy commercial vehicle adopts the form of "battery high-voltage distribution box + five-in-one controller", which at least has low integration and high development cost. The five-in-one controller, the insulation detection unit and the high-voltage distribution box are integrated and set, and a dual-branch dual-charging and distribution solution is adopted to reduce connectors and long-distance leads to improve integration and reduce development costs, and the five-in-one controller realizes the charging function to improve the reliability and safety of the battery system and the whole vehicle.

[0005] The utility model provides a controller device for a vehicle, comprising: a shell and a controller body, the controller body being adapted to the shell; the controller body comprising: a five-in-one controller and other functional units; the five-in-one controller comprising: a main drive functional unit, a PDU functional unit, a DC-DC functional unit, an oil pump functional unit and an air pump functional unit; the other functional units comprising: an insulation detection unit and a battery high-voltage power distribution unit; the battery high-voltage power distribution unit having a charging and distribution branch; wherein the five-in-one controller is integrated with the insulation detection unit and the battery high-voltage power distribution unit; and / or, in the battery high-voltage power distribution unit, the number of the charging and distribution branches is at least two; at least two of the charging and distribution branches are connected in parallel; wherein, when the five-in-one controller, the battery high-voltage power distribution unit and the insulation detection unit are integrated, and the number of the charging and distribution branches is at least two, a dual-branch six-in-one integrated controller is obtained.

[0006] In some embodiments, in the battery high-voltage distribution unit, at least two of the charging and distribution branches include a first charging and distribution branch and a second charging and distribution branch; the first charging and distribution branch and the second charging and distribution branch have the same structure; wherein the first charging and distribution branch includes: a first main positive branch connected to an external first battery pack, a first main negative branch, and a first fast charging branch; a first MSD switch is provided in the first main positive branch, and the positive electrode of the external first battery pack is connected to the main circuit high-voltage positive electrode of the vehicle's controller device after passing through the first MSD switch; a first CAN current sensor is provided in the first main negative branch, and the negative electrode of the external first battery pack is connected to the main circuit high-voltage negative electrode of the vehicle's controller device after passing through the first CAN current sensor; the insulation detection unit is provided between the main circuit high-voltage positive electrode and the main circuit high-voltage negative electrode, and the insulation detection unit is located at the rear side of the first main negative branch; a main negative relay is provided on the main circuit high-voltage negative electrode, and the main negative relay is located at the rear side of the insulation detection unit and at the front side of the first fast charging branch.

[0007] In some embodiments, a first positive branch relay and a first negative branch relay are provided in the first fast charging branch; wherein, the positive pole of the first fast charging branch is connected to the high-voltage positive pole of the main circuit via the first positive branch relay, and the negative pole of the first fast charging branch is connected to the high-voltage negative pole of the main circuit via the first negative branch relay.

[0008] In some embodiments, the PDU functional unit in the five-in-one controller includes: an air conditioning control interface, a battery heating interface, a PTC interface, and a defrost interface; wherein, adapted to each interface in the PDU functional unit in the five-in-one controller, an interface relay and an interface fuse corresponding to each interface are provided; the main circuit high-voltage positive electrode of the vehicle's controller device is connected to the positive electrode of each interface after passing through the interface relay and the interface fuse corresponding to each interface; the negative electrode of each interface is connected to the main circuit high-voltage negative electrode of the vehicle's controller device; the PDU functional unit in the dual-branch six-in-one integrated controller includes the PDU in the five-in-one controller The DU functional unit also includes a TMS control interface and a reserved interface; wherein a TMS relay is provided to match the TMS control interface; the high-voltage positive pole of the main circuit of the vehicle's controller device is connected to the positive pole of the TMS control interface after passing through the TMS relay; the negative pole of the TMS control interface is connected to the high-voltage negative pole of the main circuit of the vehicle's controller device; a reserved relay and a reserved fuse are provided to match the reserved interface; the high-voltage positive pole of the main circuit of the vehicle's controller device is connected to the positive pole of the reserved interface after passing through the reserved relay and the reserved fuse; the negative pole of the reserved interface is connected to the high-voltage negative pole of the main circuit.

[0009] In some embodiments, the number of the battery heating interfaces is the same as the number of battery packs connected to at least two of the charging and distribution branches; when the at least two charging and distribution branches are two charging and distribution branches, the battery heating interface is a first battery heating interface and a second battery heating interface; a battery heating relay, a first heating fuse and a second heating fuse are provided to match the first battery heating interface and the second battery heating interface; the high-voltage positive pole of the main circuit of the controller device of the vehicle is divided into two paths after passing through the battery heating relay: one path is connected to the positive pole of the first battery heating interface after passing through the first heating fuse, and the other path is connected to the positive pole of the second battery heating interface after passing through the second heating fuse; the negative pole of the first battery heating interface is connected to the high-voltage negative pole of the main circuit of the controller device of the vehicle, and the negative pole of the second battery heating interface is connected to the high-voltage negative pole of the main circuit of the controller device of the vehicle.

[0010] In some embodiments, the DC-DC functional unit in the five-in-one controller includes: a DC-DC module and a charging fuse; wherein the main circuit high-voltage positive electrode of the vehicle's controller device is connected to the input end of the DC-DC module after passing through the charging fuse; the first connection end of the output end of the DC-DC module is connected to the first connection end of the vehicle's battery, the second connection end of the output end of the DC-DC module is connected to the second connection end of the vehicle's battery, and the ground end of the DC-DC module is connected to the main circuit high-voltage negative electrode of the vehicle's controller device; and / or, the main drive functional unit in the five-in-one controller includes: a main drive fuse, a main drive pre-charging relay, a main drive pre-charging resistor and a main drive relay; wherein the main circuit high-voltage positive electrode of the vehicle's controller device is divided into a main drive pre-charging circuit and a main drive main circuit after passing through the main drive fuse, and the main drive pre-charging circuit and the main drive main circuit are connected in parallel and then output to the inverter in the vehicle's motor controller; the main drive pre-charging relay and the main drive pre-charging resistor are connected in series in the main drive pre-charging circuit, The main drive relay is arranged in the main drive main circuit; and / or, adapted to the oil pump function unit and the air pump function unit in the five-in-one controller, an auxiliary drive function unit is arranged; the auxiliary drive function unit includes: an auxiliary drive relay, an auxiliary drive pre-charging relay and an auxiliary drive pre-charging resistor, the auxiliary drive relay is arranged in the auxiliary drive main circuit, the auxiliary drive pre-charging relay and the auxiliary drive pre-charging resistor are connected in series in the auxiliary drive pre-charging circuit; the oil pump function unit includes an oil pump fuse, an EPS module and an oil pump motor interface, the air pump function unit includes an air pump fuse, A IR module and air pump motor interface; wherein, the high-voltage positive pole of the main circuit of the vehicle's controller device is divided into two paths after passing through the auxiliary drive main circuit and the auxiliary drive pre-charging circuit in parallel: one path is connected to the oil pump motor interface after passing through the oil pump fuse and the EPS module, and the negative pole of the EPS module is connected to the high-voltage negative pole of the main circuit of the vehicle's controller device; the other path is connected to the air pump motor interface after passing through the air pump fuse and the AIR module, and the negative pole of the AIR module is connected to the high-voltage negative pole of the main circuit of the vehicle's controller device.

[0011] In some embodiments, the shell is formed by high-pressure casting of ADC12 material, and the accommodating space inside the shell is divided into a first cavity, a second cavity and a heat dissipation area; wherein the first cavity and the second cavity are arranged vertically, and the controller body is disposed in the first cavity and the second cavity; the heat dissipation area is located between the first cavity and the second cavity, and the heat dissipation area is provided with a series liquid-cooled heat dissipation channel for dissipating the heat of the heating elements in the controller body.

[0012] In some embodiments, a sheet metal part is arranged in the first area in the first cavity, and a main control board and a bus capacitor in the controller body are mounted on the sheet metal part; the functional modules on the main control board include: at least one of a power supply module, a communication module, a minimum system, a main drive control module, a PDU relay control module, a current sampling circuit, a voltage sampling circuit, an insulation detection unit and a high-voltage interlocking module in the controller body; the bus capacitor is connected to an inverter in a motor controller in a controller device of the vehicle; and / or a PDU converter is also arranged in the second area in the first cavity. The connecting board and the PDU copper busbar, the PDU adapter board, the PDU copper busbar, and the PDU fuse and PDU relay in the PDU functional unit in the controller body are integrated; the input and output ends of the PDU relay are electrically connected and fixed to the PDU adapter board, and the PDU copper busbar is connected to the output end of the MSD switch in the controller body; the PDU fuse is installed on the PDU adapter board; wherein the PDU fuse includes: a fuse of an air-conditioning module, a fuse of a PTC module, a fuse of a defrost module, a fuse of a DC-DC module, and a fuse of a reserved interface arranged in sequence.

[0013] In some embodiments, a flow channel cover plate is provided to match the series liquid-cooled heat dissipation flow channel; the flow channel cover plate is welded to the series liquid-cooled heat dissipation flow channel at the heat dissipation area in the shell; in the second cavity, the DC-DC module and the auxiliary drive inverter in the controller body are installed on the flow channel cover plate; the auxiliary drive drive board in the controller body is welded to the auxiliary drive inverter, the auxiliary drive inverter, the auxiliary drive drive board, and the auxiliary drive main control board in the controller body are all installed on the inner wall of the shell, and the auxiliary drive drive board is electrically connected to the auxiliary drive main control board through a wiring harness; the main control board in the controller body is respectively electrically connected to the weak current interface of the DC-DC module and the weak current interface of the auxiliary drive main control board through a wiring harness; and / or, the controller is provided on the first surface outside the shell. The high-voltage input interface, fast-charging input interface and three-phase output interface of the controller body; the high-voltage input interface, fast-charging input interface and three-phase output interface of the controller body are all connected to the power line using a through-hole connector, and the through-hole connector is installed on the internal junction box of the shell through a sealed socket; and / or, on the second surface outside the shell, the MSD interface, battery heating interface, PDU interface and auxiliary drive interface of the controller body are arranged; the PDU interface includes: an air-conditioning interface, a TMS interface, a PTC interface, a defrost interface and a PTC interface arranged in sequence; the auxiliary drive interface includes: an oil pump interface and an air pump interface; and / or, on the third surface outside the shell, the weak-current signal interface and battery interface of the controller body are arranged, and a water outlet and a water inlet adapted to the series liquid-cooled heat dissipation channel are also arranged.

[0014] Matching the controller device of the above-mentioned vehicle, the utility model further provides a new energy commercial vehicle, including: the controller device of the above-mentioned vehicle.

[0015] Therefore, the solution of the utility model integrates the five-in-one controller, insulation detection unit and high-voltage distribution box for the vehicle and the high-voltage distribution box for realizing the high-voltage distribution function; thus, by integrating the five-in-one controller, insulation detection unit and high-voltage distribution box, the use of connectors is reduced, and long-distance leads are reduced, which is conducive to improving integration and reducing development costs. At the same time, the high-voltage distribution function adopts a dual-branch dual-charging distribution solution, the dual branches are connected in parallel and can be externally connected to two power battery packs to form a dual-branch six-in-one controller for the vehicle; by adopting a dual-branch dual-charging distribution solution for the high-voltage distribution function, when one of the dual branches fails, the other branch can continue to supply power to the vehicle to ensure normal driving of the vehicle, which is conducive to improving the reliability and safety of the vehicle's battery system and the entire vehicle.

[0016] Other features and advantages of the present invention will be set forth in the following description, and in part will become apparent from the description, or may be understood by practicing the present invention.

[0017] The technical solution of the utility model is further described in detail below through the accompanying drawings and embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is a structural schematic diagram of an embodiment of a dual-branch six-in-one controller for a new energy commercial vehicle of the utility model;

[0019] Figure 2 It is the electrical principle diagram of the dual-branch six-in-one controller;

[0020] Figure 3 It is an exploded diagram of the overall structure of the dual-branch six-in-one controller;

[0021] Figure 4 Schematic diagram of the installation structure of the top surface of the dual-branch six-in-one controller (a);

[0022] Figure 5 Schematic diagram of the installation structure of the top surface of the dual-branch six-in-one controller (b);

[0023] Figure 6 It is a schematic diagram of the installation structure of the bottom surface of the dual-branch six-in-one controller;

[0024] Figure 7 This is a schematic diagram of the front installation structure of a dual-branch six-in-one controller;

[0025] Figure 8 This is the left view of the dual-branch six-in-one controller;

[0026] Fig. 9 This is the right view of the dual-branch six-in-one controller;

[0027] Fig.10 Schematic diagram of an isometric view of a dual-branch six-in-one controller.

[0028] In conjunction with the accompanying drawings, the reference numerals in the embodiments of the present invention are as follows:

[0029] 1-PDU fuse cover; 2-controller top cover; 3-main control board; 4-weak current signal interface; 5-sheet metal; 6-busbar capacitor; 7-drive board; 8-inverter; 9-debugging interface; 10-controller housing; 11-current sensor; 12-water outlet; 13-water inlet; 14-battery interface; 15-junction box; 16-DC-DC module; 17-auxiliary drive inverter; 18-auxiliary drive drive board; 19-auxiliary drive main control board; 20-controller bottom cover; 21-junction box cover; 22-through-hole connector; 23-auxiliary drive interface; 24-PDU connector 25-MSD; 26-copper busbar; 27-PDU relay support sheet metal; 28-CAN current sensor; 29-PDU relay; 30-battery heating interface; 31-PDU adapter board; 32-PDU copper busbar; 33-PDU fuse; 34-main fuse F1; 35-main fuse support; 36-relay K2; 37-pre-charge resistor R2; 38-discharge resistor; 39-relay K11; 40-relay K13; 41-relay K14; 42-relay K12; 43-relay K15; 44-flow channel cover. DETAILED DESCRIPTION

[0030] 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. Obviously, the described embodiments are only part of the embodiments of the utility model, not all of the 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.

[0031] Considering that the control of the power system of new energy commercial vehicles adopts the form of "battery high-voltage distribution box + five-in-one controller", the battery high-voltage distribution box is generally customized by the power battery manufacturer according to the vehicle model requirements of the vehicle manufacturer. This customized solution is not conducive to the standardized production of battery modules. The cost of the battery high-voltage distribution box is high, and the two controllers (i.e. the controller of the battery high-voltage distribution box + the five-in-one controller) occupy more space in the vehicle, and the wiring harness and connectors connecting the two further increase the cost. With the development of various new technologies, the controller of new energy commercial vehicles is developing towards low cost, high integration and multi-function while ensuring high safety and high quality.

[0032] Some solutions provide an all-in-one controller for new energy commercial vehicles, including a controller shell, an upper bottom surface and a lower bottom surface are arranged in parallel inside the controller shell, a battery / motor high-voltage interface module is arranged on the front side of the outside of the controller shell, a high-voltage and low-current output interface, a low-voltage communication interface and a 24V voltage interface are arranged on the right side of the outside of the controller shell, and a large-current and high-voltage interface is arranged on the rear side of the outside of the controller shell. A microcontroller unit (MCU) functional area, a power distribution unit (PDU) functional area and a filter module are arranged on the upper bottom surface, the MCU functional area is electrically connected to the battery / motor high-voltage interface module through the filter module, the MCU functional area is electrically connected to the PDU functional area, and the PDU functional area is electrically connected to the high-voltage and low-current output interface and the large-current and high-voltage interface respectively, the MCU functional area is arranged on the front side of the upper bottom surface, the PDU functional area is arranged on the rear of the upper bottom surface, and the filter module is arranged on the right side of the MCU functional area.

[0033] There are also some schemes that provide battery control devices, methods, and electric vehicles for electric vehicles. The battery control device includes: a battery module; two charging circuits connected to the battery module, each charging circuit including a charging relay and a pair of charging ports connected in series; and a control module, the control module is configured to: when the first charging gun charges the battery module through the charging port of one charging circuit, when it is detected that the second charging gun is connected to the charging port of another charging circuit, first make the requested charging current of the battery module 0, and then charge the battery module with the first charging gun and the second charging gun. The present disclosure can realize the single-gun charging function and the dual-gun charging function, and can protect the performance of the relay in the process of switching from the single-gun charging mode to the dual-gun charging mode.

[0034] Some other solutions provide dual-branch high-voltage control circuits and control boxes thereof, wherein the dual-branch high-voltage control circuit includes two power branches, each power branch includes a battery pack, a battery management system (BMU) management unit, a discharge device, a charging device and a control circuit, and the control circuit includes a secondary main control, a discharge positive relay, a discharge negative relay, a charging positive relay and a charging negative relay; the control box includes a box body and a cover body, the box body is provided with a control circuit, and the box body is provided with an interface for electrically connecting the control circuit with the battery pack, the BMU management unit, the discharge device and the charging device; each power branch is provided with a secondary main control, a discharge positive relay, a discharge negative relay, a charging positive relay and a charging negative relay, and when the relay on one power branch is cut off by the secondary main control, the other power branch can still continue to supply power to the vehicle, eliminating the safety hazards that exist during the driving of the vehicle.

[0035] However, in the above solution, the battery high-voltage distribution box and the five-in-one controller are still set up independently. The five-in-one controller does not have an integrated battery high-voltage distribution box. The five-in-one controller does not have two-way fast charging, no manual maintenance switch (Manual Service Disconnect, MSD), no two-way battery input, no main negative relay, and the PDU (Power Distribution Unit) does not have a thermal management system (Thermal Management System, TMS), defrosting, or battery heating functions.

[0036] Therefore, the solution of the utility model proposes a vehicle controller device, specifically a dual-branch six-in-one controller for new energy commercial vehicles, which integrates a battery high-voltage distribution box, an insulation detection unit and a five-in-one controller to improve integration and reduce development costs, and the distribution function is a dual-branch dual-charging distribution solution so that the five-in-one controller has a charging function, which not only solves the problem of low integration and high development cost of the control of the power system of new energy commercial vehicles in the form of "battery high-voltage distribution box + five-in-one controller + insulation detection unit", but also solves the problem that the five-in-one controller does not have a charging function.

[0037] According to an embodiment of the present invention, a controller device for a vehicle is provided. Figure 1 The schematic diagram of the structure of an embodiment of the controller device of the vehicle of the utility model is shown. The controller device of the vehicle may include: a shell and a controller body, the shell is such as the controller shell 10, the controller body is such as a five-in-one controller and a high-voltage distribution box for realizing the high-voltage power distribution function; the controller body is adapted to be arranged with the shell, specifically, the controller body is adapted to be arranged in the shell and / or on the shell; the controller body includes: a five-in-one controller and other functional units, the high-voltage power distribution functional unit is such as a high-voltage distribution box for realizing the high-voltage power distribution function; the five-in-one controller includes: a main drive functional unit, a PDU functional unit, a DC-DC (i.e., direct current to direct current) functional unit, an oil pump functional unit and an air pump functional unit; the other functional units include: an insulation detection unit and a battery high-voltage distribution unit; the battery high-voltage distribution unit has a charging and distribution branch.

[0038] Among them, the five-in-one controller is integrated with the insulation detection unit and the battery high-voltage distribution unit, for example: the five-in-one controller, the battery high-voltage distribution unit and the insulation detection unit are integrated, that is, the five-in-one controller is integrated with the battery high-voltage distribution box to reduce the use of connectors and the use of long-distance leads, which is conducive to improving integration and reducing development costs; and / or, in the battery high-voltage distribution unit, the number of charging and distribution branches is at least two; at least two charging and distribution branches are connected in parallel, used to connect at least two power battery packs, when at least one of the two branches fails, the remaining branches can continue to supply power to the vehicle to ensure normal driving of the vehicle, which is conducive to improving the reliability and safety of the vehicle's battery system and the entire vehicle. Among them, when the five-in-one controller, the battery high-voltage distribution unit and the insulation detection unit are integrated, and the number of the charging and distribution branches is at least two, a dual-branch six-in-one integrated controller (i.e., a dual-branch six-in-one controller) is obtained.

[0039] The solution of the utility model proposes a vehicle controller device, which integrates a battery high-voltage distribution box, an insulation detection unit and a five-in-one controller through the design of the control assembly and the controller shell. Its functions include main drive, PDU, DC-DC, oil pump and air pump. After integration, the use of connectors is reduced, long-distance leads are reduced, development costs are reduced, and integration is higher, which solves the problems of low integration and high development costs of the original five-in-one controller and the battery high-voltage distribution box and insulation detection unit. The integrated design of the battery high-voltage distribution box + five-in-one controller is conducive to the standardized design of battery modules; and the power distribution function of the dual-branch six-in-one controller is a dual-branch dual-charging power distribution solution, which includes two-way input, two-way fast charging, MSD and other functions. The two branches are connected in parallel and two power battery packs are externally connected. When one of the branches fails, the other branch can continue to supply power to the vehicle, and the vehicle can drive normally. The safety of the battery system and the whole vehicle is improved, and the dual-branch dual-fast charging solution has a faster charging speed.

[0040] In some embodiments, in the battery high-voltage distribution unit, at least two of the charging and distribution branches include a first charging and distribution branch and a second charging and distribution branch, the first charging and distribution branch is such as the charging and distribution branch of the first battery pack, and the second charging and distribution branch includes the charging and distribution branch of the second battery pack; the first charging and distribution branch and the second charging and distribution branch have the same structure.

[0041] The first charging and distribution branch includes: a first main positive branch connected to an external first battery pack, a first main negative branch, and a first fast charging branch; a first MSD switch is provided in the first main positive branch, and the positive electrode of the external first battery pack is connected to the main circuit high-voltage positive electrode of the vehicle controller device through the first MSD switch; a first CAN current sensor is provided in the first main negative branch, and the negative electrode of the external first battery pack is connected to the main circuit high-voltage negative electrode of the vehicle controller device through the first CAN current sensor; The insulation detection unit is arranged between the high-voltage negative poles, and the insulation detection unit is located at the rear side of the first main negative branch, specifically, the insulation detection unit is located at the rear side of the connection end between the main negative branch of each charging and distribution branch in at least two of the charging and distribution branches and the main circuit high-voltage negative pole; a main negative relay is arranged on the main circuit high-voltage negative pole, and the main negative relay is located at the rear side of the insulation detection unit and at the front side of the first fast charging branch, specifically, the main negative relay is located at the rear side of the connection end between the insulation detection unit and the main circuit high-voltage negative pole, and at the front side of the first fast charging branch. Specifically, the battery pack external to the first charging and distribution branch, such as Figure 2 The first battery pack in the first main positive branch is as follows Figure 2 The main circuit high voltage positive electrode connected to the first battery pack, the first main negative branch is as follows Figure 2 The main circuit high voltage negative electrode connected to the first battery pack, the first MSD switch is as follows Figure 2 The first MSD, the first CAN current sensor Figure 2 The CAN current sensor T1 in the first positive branch relay is as follows Figure 2 Relay K11 in the first negative branch relay is as follows Figure 2 Relay K12 in the main negative relay is as follows Figure 2 The main negative relay K15 in the circuit. CAN refers to CAN (Controller Area Network) communication.

[0042] Figure 2 The figure is the electrical principle diagram of the dual-branch six-in-one controller. Figure 2In the example shown, the dual-branch six-in-one controller is externally connected to two battery packs, such as the first battery pack and the second battery pack. Each battery pack, each MSD and each CAN current sensor form a branch. The two branches of the two battery packs are connected in parallel. Each main positive branch connected to the battery pack includes an MSD switch, and each main negative branch includes a CAN current sensor. Among them, each main positive branch connected to the first battery pack includes a first MSD and a CAN current sensor T1, and each main positive branch connected to the second battery pack includes a second MSD and a CAN current sensor T2. The first connection end of the first battery pack is connected to the main circuit high voltage positive electrode through the first MSD; the second connection end of the first battery pack is connected to the main circuit high voltage negative electrode through the CAN current sensor T1. The first connection end of the second battery pack is connected to the main circuit high voltage positive electrode through the second MSD; the second connection end of the second battery pack is connected to the main circuit high voltage negative electrode through the CAN current sensor T2. The insulation detection unit is located between the CAN current sensor T2 and the relay K15. The first connection end of the insulation detection unit is connected to the end of the second MSD away from the second battery pack (i.e., the end of the second MSD connected to the high-voltage positive electrode of the main circuit), the second connection end of the insulation detection unit is connected to the end of the CAN current sensor T2 away from the second battery pack (i.e., the end of the CAN current sensor T2 connected to the high-voltage negative electrode of the main circuit), and the third connection end of the CAN current sensor T2 is grounded. The relay K15 is set on the high-voltage negative electrode of the main circuit, one end of the relay K15 is connected to the end of the CAN current sensor T2 away from the second battery pack, and the other end of the relay K15 is connected to the second connection end of the input end of the inverter. There is a main negative relay K15 43 on the high-voltage negative electrode of the main circuit, which can cut off the high-voltage negative electrode of the main circuit. The insulation detection unit is located in the main control board 3, and can detect the insulation resistance value of the battery bus voltage to the positive and negative ground. If the insulation performance decreases, it will cause leakage, thereby causing electric shock accidents and posing a threat to personal safety.

[0043] In the form of a five-in-one controller + a battery high-voltage distribution box in the related solutions, the five-in-one controller does not have a charging function. However, the solution of the utility model integrates a battery high-voltage distribution box into the five-in-one controller to obtain a dual-branch six-in-one controller, so that the dual-branch six-in-one controller has a charging function, and also solves the problem that the five-in-one controller does not have a charging function, which is conducive to improving the safety and reliability of the vehicle.

[0044] In some embodiments, a first positive branch relay and a first negative branch relay are provided in the first fast charging branch; wherein, the positive pole of the first fast charging branch is connected to the high-voltage positive pole of the main circuit via the first positive branch relay, the negative pole of the first fast charging branch is connected to the high-voltage negative pole of the main circuit via the first negative branch relay, and the connection end between the first negative branch relay and the high-voltage negative pole of the main circuit is located on the rear side of the main negative relay.

[0045] In such Figure 2 In the example shown, the dual-branch six-in-one controller includes two fast-charging modules such as the first fast-charging module and the second fast-charging module, and each fast-charging positive and negative branch has a relay controller. Among them, the positive branch of the first fast-charging module has a relay K11, and the negative branch of the first fast-charging module has a relay K12. The positive branch of the second fast-charging module has a relay K13, and the negative branch of the second fast-charging module has a relay K14. The first connection end of the first fast-charging module is connected to the high-voltage positive electrode of the main circuit through the relay K11; the second connection end of the first fast-charging module is connected to the high-voltage negative electrode of the main circuit through the relay K12. The first connection end of the second fast-charging module is connected to the high-voltage positive electrode of the main circuit through the relay K13; the second connection end of the second fast-charging module is connected to the high-voltage negative electrode of the main circuit through the relay K14.

[0046] In some embodiments, the PDU functional unit in the five-in-one controller includes: an air conditioning control interface, a battery heating interface, a PTC interface, and a defrosting interface; wherein, adapted to each interface in the PDU functional unit in the five-in-one controller, an interface relay and an interface fuse corresponding to each interface are provided, such as an interface relay K3 and an interface fuse F3 corresponding to the air conditioning control interface, an interface relay port and an interface fuse F8.1, F8.2 corresponding to the battery heating interface, an interface relay K8 and an interface fuse F8 corresponding to the PTC interface, and an interface relay K7 and an interface fuse F7 corresponding to the defrosting interface; the main circuit high-voltage positive electrode of the vehicle's controller device is connected to the positive electrode of each interface after passing through the interface relay and the interface fuse corresponding to each interface; the negative electrode of each interface is connected to the main circuit high-voltage negative electrode of the vehicle's controller device. Wherein, PTC (Positive Temperature Coefficient) represents a positive temperature coefficient, which is a PTC thermistor.

[0047] The PDU functional unit in the dual-branch six-in-one integrated controller includes the PDU functional unit in the five-in-one controller, and also includes a TMS control interface and a reserved interface; wherein, a TMS relay (such as Figure 2The relay K9 in the vehicle controller is connected to the positive pole of the main circuit of the vehicle controller through the TMS relay; the negative pole of the TMS control interface is connected to the negative pole of the main circuit of the vehicle controller. The reserved interface is matched with the reserved relay and the reserved fuse. The reserved relay is as follows: Figure 2 Relay K7 in the reserve fuse is as follows Figure 2 The fuse F7 in the vehicle controller device; the high-voltage positive pole of the main circuit is connected to the positive pole of the reserved interface after passing through the reserved relay and the reserved fuse; the negative pole of the reserved interface is connected to the high-voltage negative pole of the main circuit.

[0048] In such Figure 2 In the example shown, the PUD function of the dual-branch six-in-one controller adds a TMS (such as TMS of high-voltage cooling and heating units) control function compared to the air conditioning function, battery heating function, PTC function, and defrost function of the original five-in-one controller, and additional PDU function branches and interfaces are reserved. Each function branch is controlled and protected by a combination of relays and fuses. The first connection end of the TMS module is connected to the high-voltage positive pole of the main circuit through relay K9; the second connection end of the TMS module is connected to the high-voltage negative pole of the main circuit. Among them, the role of the additional reserved PDU function branch and interface is: one more PDU control function, such as electric heating control function, etc., to match the vehicle model that requires more functions. The additional reserved PDU function branch includes: one PDU function branch, the interior of which is also connected to the reserved relays and fuses.

[0049] In such Figure 2 In the example shown, the high-voltage positive electrode of the main circuit is connected to the first connection end of the reserved interface module through relay K16 and fuse F16, and the second connection end of the reserved interface module is connected to the high-voltage negative electrode of the main circuit. The high-voltage positive electrode of the main circuit is connected to the first connection end of the defrost module through relay K7 and fuse F7; the second connection end of the defrost module is connected to the high-voltage negative electrode of the main circuit. The high-voltage positive electrode of the main circuit is connected to the first connection end of the PTC module through relay K8 and fuse F8; the second connection end of the PTC module is connected to the high-voltage negative electrode of the main circuit. The high-voltage positive electrode of the main circuit is connected to the first connection end of the air-conditioning module through relay F3 and fuse F3, and the second connection end of the air-conditioning module is connected to the high-voltage negative electrode of the main circuit.

[0050] In the related scheme, the five-in-one controller for commercial vehicles is integrated with a single motor controller and a four-in-one distribution box. The output end of the power battery pack of the commercial vehicle, that is, the input end of the five-in-one controller, also has a battery high-voltage distribution box. The MSD, main negative relay, fast charge positive and negative relay, and main negative current sensor included in the battery high-voltage distribution box are all not available in the five-in-one controller. The scheme of the utility model integrates the five-in-one controller with the battery high-voltage distribution box, rather than the form of a five-in-one controller + a battery high-voltage distribution box, to obtain a dual-branch six-in-one controller for new energy commercial vehicles; by integrating the battery high-voltage distribution box with the original five-in-one controller, the integration can be improved and the development cost can be reduced, solving the problem of long leads and transmission loss between the original five-in-one controller and the battery high-voltage distribution box, and the integrated design of the battery high-voltage distribution box + five-in-one controller is conducive to the standardized design of the battery module, thereby solving the problem of low integration and high development cost of the original five-in-one and the battery high-voltage distribution box.

[0051] In some embodiments, the number of the battery heating interfaces is the same as the number of battery packs connected to at least two of the charging and distribution branches; in the case where at least two of the charging and distribution branches are two charging and distribution branches, the battery heating interfaces are the first battery heating interface and the second battery heating interface; a battery heating relay, a first heating fuse and a second heating fuse are provided to match the first battery heating interface and the second battery heating interface; the high-voltage positive pole of the main circuit of the vehicle's controller device is divided into two paths after passing through the battery heating relay: one path is connected to the positive pole of the first battery heating interface after passing through the first heating fuse, and the other path is connected to the positive pole of the second battery heating interface after passing through the second heating fuse; the negative pole of the first battery heating interface is connected to the high-voltage negative pole of the main circuit of the vehicle's controller device, and the negative pole of the second battery heating interface is connected to the high-voltage negative pole of the main circuit of the vehicle's controller device. Wherein, the battery heating relay is as follows: Figure 2 Relay K4 in the first heating fuse is as follows Figure 2 The fuse F8.1 in the second heating fuse is as follows Figure 2 Fuse F8.2 in.

[0052] In such Figure 2In the example shown, the PUD function of the dual-branch six-in-one controller adds a TMS (such as the TMS of the high-voltage cooling and heating unit) control function compared to the air conditioning function, battery heating function, PTC function, and defrost function of the original five-in-one controller, and additional PDU functional branches and interfaces are reserved. Each functional branch is controlled and protected by a combination of relays and fuses. Since there are two battery packs, the PDU includes two battery heating functions (such as the first battery heating module and the second battery heating module), which are controlled by a relay K8 and protected by two fuses (i.e., fuse F8.1 and fuse F8.2). The first connection end of the TMS module is connected to the high-voltage positive electrode of the main circuit through relay K9; the second connection end of the TMS module is connected to the high-voltage negative electrode of the main circuit. The first connection end of the first battery heating module is connected to the first connection end of the fuse F8.1, and the second connection end of the first battery heating module is connected to the high-voltage negative electrode of the main circuit; the first connection end of the second battery heating module is connected to the first connection end of the fuse F8.2, and the second connection end of the second battery heating module is connected to the high-voltage negative electrode of the main circuit; the second connection end of the fuse F8.1 and the second connection end of the fuse F8.2 are connected, and then connected to the high-voltage positive electrode of the main circuit through the relay K4.

[0053] In some embodiments, the DC-DC functional unit in the five-in-one controller includes: a DC-DC module and a charging fuse, the charging fuse being such as fuse F4; wherein, the high-voltage positive pole of the main circuit of the controller device of the vehicle is connected to the input end of the DC-DC module after passing through the charging fuse; the first connection end of the output end of the DC-DC module is connected to the first connection end of the battery of the vehicle, the second connection end of the output end of the DC-DC module is connected to the second connection end of the battery of the vehicle, and the ground end of the DC-DC module is connected to the high-voltage negative pole of the main circuit of the controller device of the vehicle.

[0054] In such Figure 2 In the example shown, the high-voltage direct current outputted from the high-voltage positive electrode of the main circuit is converted into low-voltage direct current by the DC-DC module through the fuse F4 to charge the low-voltage battery. Specifically, the high-voltage positive electrode of the main circuit is connected to the battery after passing through the fuse F4 and the DC-DC module, the first connection end of the battery is connected to the first connection end of the DC-DC module, the second connection end of the battery is connected to the second connection end of the DC-DC module, and the third connection end of the DC-DC module is connected to the high-voltage negative electrode of the main circuit.

[0055] In some embodiments, the main drive functional unit in the five-in-one controller includes: a main drive fuse, a main drive pre-charge relay, a main drive pre-charge resistor and a main drive relay, and the main drive fuse is as follows: Figure 2 The fuse F1 in the main drive pre-charge relay is as follows Figure 2Relay K1 in the main drive pre-charging resistor is as follows Figure 2 The resistor R2 in the main drive relay is as follows Figure 2 Relay K2 in; wherein, the high-voltage positive pole of the main circuit of the vehicle's controller device is divided into a main drive pre-charging circuit and a main drive main circuit after passing through the main drive fuse, and the main drive pre-charging circuit and the main drive main circuit are connected in parallel and output to the inverter in the vehicle's motor controller; the main drive pre-charging relay and the main drive pre-charging resistor are connected in series in the main drive pre-charging circuit, and the main drive relay is arranged in the main drive main circuit.

[0056] In such Figure 2 In the example shown, the main drive circuit is divided into a pre-charging circuit and a main circuit after passing through the main fuse F1 34. The pre-charging circuit is mainly composed of a relay K1 and a pre-charging resistor R2 37, and the main circuit is mainly composed of a relay K2 36. Specifically, the high-voltage positive pole of the main circuit is divided into two paths after passing through the main fuse F1 34: one path is connected to the anode of the diode D1 after passing through the relay K1 and the pre-charging resistor R2 37, and the cathode of the diode D1 is connected to the first connection end of the input end of the inverter; the other path is connected to the first connection end of the input end of the inverter after passing through the relay K2. The high-voltage negative pole of the main circuit is connected to the second connection end of the input end of the inverter. The capacitor C1 and the resistor R3 are connected in parallel between the first connection end and the second connection end of the input end of the inverter. The output end of the inverter can output three-phase alternating current U, V, and W to the motor M. When the pre-charging is completed, the relay K2 36 is closed to prevent the charging current from being too large when the power is directly turned on. The excessive instantaneous current may cause damage to the relay K2 36 and the bus capacitor 6 (such as capacitor C1).

[0057] In some embodiments, an auxiliary drive functional unit is provided to match the oil pump functional unit and the air pump functional unit in the five-in-one controller; the auxiliary drive functional unit includes: an auxiliary drive relay, an auxiliary drive pre-charging relay and an auxiliary drive pre-charging resistor, the auxiliary drive relay is such as relay K6, the auxiliary drive pre-charging relay is such as relay K5, the auxiliary drive pre-charging resistor is such as resistor R1, the auxiliary drive relay is arranged in the auxiliary drive main circuit, the auxiliary drive pre-charging relay and the auxiliary drive pre-charging resistor are connected in series in the auxiliary drive pre-charging circuit; the oil pump functional unit includes an oil pump fuse, an EPS module and an oil pump motor interface, the air pump functional unit includes an air pump fuse, an AIR module and an air pump motor interface, the oil pump fuse is such as fuse F6, and the air pump fuse is such as fuse F5. Among them, the high-voltage positive pole of the main circuit of the vehicle's controller device is divided into two paths after passing through the auxiliary drive main circuit and the auxiliary drive pre-charging circuit in parallel: one path is connected to the oil pump motor interface after passing through the oil pump fuse and the EPS module, and the negative pole of the EPS module is connected to the high-voltage negative pole of the main circuit of the vehicle's controller device; the other path is connected to the air pump motor interface after passing through the air pump fuse and the AIR module, and the negative pole of the AIR module is connected to the high-voltage negative pole of the main circuit of the vehicle's controller device. That is, the high-voltage positive pole of the main circuit of the vehicle's controller device is output to the oil pump functional unit and the air pump functional unit respectively after passing through the auxiliary drive main circuit and the auxiliary drive pre-charging circuit in parallel.

[0058] In such Figure 2 In the example shown, the auxiliary drive circuit also includes a pre-charging circuit (i.e., a pre-charging circuit mainly composed of relay K5 and pre-charging resistor R1) and a main circuit (i.e., a main circuit mainly composed of relay K6). The pre-charging resistor R1 is located in the main control board 3. After the pre-charging is completed, the main circuit outputs to the oil and gas pump (i.e., the air pump motor and the oil pump motor) through the fuse (such as fuse F5 and fuse F6). Specifically, the high-voltage positive electrode of the main circuit is connected to the anode of the diode D2 after passing through the relay K5 and the pre-charging resistor R1, and the cathode of the diode D2 is connected to the air pump motor after passing through the fuse F5 and the AIR module. The high-voltage positive electrode of the main circuit is also connected to the diode D2 after passing through the relay K6; the high-voltage positive electrode of the main circuit is also connected to the oil pump motor after passing through the relay K6 and the fuse F6 and the EPS module.

[0059] In general, if Figure 2As shown, the circuit structure of the dual-branch six-in-one controller includes: a first battery pack, a second battery pack, a first MSD, a second MSD, a CAN current sensor T1, a CAN current sensor T2, an insulation detection unit, a first fast charging module, a second fast charging module, a TMS module, a first battery heating module, a second battery heating module, a battery module, an air conditioning module, a PTC module, a defrost module, a reserved interface, an oil pump motor module, an air pump motor module, an inverter, a diode D1, a diode D2, a capacitor C1, a resistor R1, a resistor R2 , resistor R3, relay K1, relay K2, relay K5, relay K6, relay K16, relay K7, relay K8, relay K3, relay K4, relay K9, relay K11, relay K12, relay K13, relay K14, fuse F1, fuse F5, fuse F6, fuse F16, fuse F7, fuse F8, fuse F3, fuse F8.1, fuse F8.2, DC-DC module, electric power steering system (EPS), gas pump (AIR). Figure 2 In the figure, 'K' stands for relay, 'F' stands for fuse, 'C' stands for capacitor, 'R' stands for resistor, and 'T' stands for current sensor.

[0060] In some embodiments, the shell is formed by high-pressure casting of ADC12 material, and the accommodating space inside the shell is divided into a first cavity, a second cavity and a heat dissipation area; wherein, the first cavity and the second cavity are arranged up and down (i.e., corresponding intervals are arranged up and down), and the controller body is arranged in the first cavity and the second cavity; the heat dissipation area is located between the first cavity and the second cavity, and the heat dissipation area is provided with a series liquid-cooled heat dissipation channel for dissipating the heat of the heating elements in the controller body.

[0061] Figure 3 This is an exploded diagram of the overall structure of the dual-branch six-in-one controller. Figure 3It is an exploded view of a dual-branch six-in-one controller, including: PDU fuse cover 1, controller top cover 2, main control board 3, weak current signal interface 4, sheet metal 5, bus capacitor 6, drive board 7, inverter 8, debugging interface 9, controller housing 10, current sensor 11, water outlet 12, water inlet 13, battery interface 14, junction box 15, DC-DC module 16, auxiliary drive inverter 17, auxiliary drive drive board 18, auxiliary drive main control board 19, controller bottom cover 20, junction box cover 21, through-hole connector 22, auxiliary drive interface 23, PDU interface 24, MSD 25, copper busbar 26, PDU relay support sheet metal 27, CAN current sensor 28, PDU relay 29, battery heating interface 30, PDU adapter board 31, PDU copper busbar 32, PDU fuse 33, main fuse F1 34, main fuse support 35, relay K2 36. Pre-charging resistor R2 37. Discharging resistor 38. Relay K11 39. Relay K13 40. Relay K14 41. Relay K12 42. Relay K15 43. Flow channel cover 44.

[0062] The controller housing 10 is made of ADC12 material by high pressure casting. The housing is divided into an upper and lower cavity. There is a series liquid cooling heat dissipation channel between the two cavities, which can dissipate heat for the heating elements of the upper and lower cavities at the same time, not only meeting the heat dissipation requirements, but also improving the heat dissipation effect. ADC12 is also called No. 12 aluminum material, Al-Si-Cu alloy, a die-cast aluminum alloy suitable for cylinder head cover, sensor bracket, cylinder body, etc. The implementation standard is: JIS H 5302-2006 "Aluminum Alloy Die Castings".

[0063] In some embodiments, a sheet metal part 5 is provided in the first area in the first cavity, and a main control board 3 and a bus capacitor 6 in the controller body are mounted on the sheet metal part 5; the functional modules on the main control board 3 include: at least one of a power supply module, a communication module, a minimum system, a main drive control module, a PDU relay control module, a current sampling circuit, a voltage sampling circuit, an insulation detection unit and a high-voltage interlocking module in the controller body; the bus capacitor 6 is connected to the inverter in the motor controller in the controller device of the vehicle; the first area in the first cavity, such as the right area of ​​the first cavity.

[0064] Figure 4 The schematic diagram of the top surface installation structure of the dual-branch six-in-one controller (a) is shown. Figure 5 Figure 1 is a schematic diagram of the top surface installation structure of a dual-branch six-in-one controller (b). Figure 4 and Figure 5As shown in the schematic diagram of the installation structure of the top surface of the dual-branch six-in-one controller shown, the main control board 3 is fixed to the sheet metal 5 by screws. The functions of the main control board 3 include power module, communication module, minimum system, main drive control module, PDU relay control module, current sampling circuit, voltage sampling circuit, insulation detection unit, high-voltage interlocking module and other circuits. Among them, the minimum system includes functional modules such as central processing unit, memory, input and output ports and timer, which are used to provide powerful data processing and control capabilities. The current sampling circuit can collect the output current of the three phases U, V, and W of the controller to prevent overcurrent and protect the controller; the voltage sampling circuit can collect the voltage of each branch and the main circuit, can monitor the status of the controller and components, and also has overvoltage protection and undervoltage protection functions. The high-voltage interlocking module can monitor whether the connector is normally connected. If the connection is abnormal, the controller cannot be powered on normally. The insulation detection unit is integrated in the main control board 3 and is connected to the main control board 3. Figure 2The positive electrodes of the first and second battery packs connected in parallel are connected to detect the insulation resistance of the power battery to the vehicle ground. When the insulation resistance of the vehicle decreases, the leakage current will increase. When the leakage current reaches a certain value, it will cause harm to personal safety and the operation of the vehicle electrical system. The sheet metal part 5 is fixed to the controller housing 10 and the busbar capacitor 6 by screws. The high-voltage direct current in the battery pack is stored in the bus capacitor 6 after passing through the MSD 25, the main fuse F1 34, and the main relay K1 36. The bus capacitor 6 can smooth the bus voltage, weaken the peak voltage of the bus, and make the bus voltage relatively smooth when the inverter 8 is switched. The main fuse F1 34 is fixed to the main fuse support 35 by screws, and the main fuse support 35 is fixed to the controller housing 10 by screws; the drive board 7 is fixed to the inverter 8 by screws, and the drive board 7 and the inverter 8 form an inverter unit, which converts the high-voltage direct current into U, V, and W three-phase alternating current and outputs it to the motor M through the copper bus. Current sensors 11 are respectively installed on the U-phase and V-phase output copper buses. The current sensor 11 performs current sampling, and the W-phase current can be calculated by referring to the sampled currents of the other two phases. The weak current interfaces of the drive board 7 and the current sensor 11 are respectively electrically connected to the main control board 3 through wiring harnesses. Relay K11 39 and relay K13 40 are respectively the positive relay of the second fast charging module and the positive relay of the first fast charging module, and are fixed to the controller housing 10 by screws, and are connected to the positive poles of the two battery packs and the fast charging input interface through a copper busbar; relay K14 41, relay K1242, and relay K15 43 are respectively the negative relay of the second fast charging module, the negative relay of the first fast charging module, and the main negative relay. All three relays are connected to the negative pole of the bus capacitor 6 through a copper busbar, one end of relay K14 41 and relay K12 42 is connected to the negative pole of the battery pack through relay K15 43, and the other end of relay K14 41 and relay K12 42 is connected to the negative pole interface of the fast charging module through a copper busbar. The negative copper bars of the two battery packs are respectively equipped with CAN current sensors 28, which can directly convert electrical signals into CAN communication messages and send the messages to the BMS mainboard of the battery pack. The weak current interface of the CAN current sensor 28 is electrically connected to the main control board 3 through a wiring harness. When the current in the circuit is too large, the main negative relay K15 43 will automatically cut off the current, thereby protecting the circuit and load equipment from damage. The main control board 3 is electrically connected to the weak current interface of the above relay to control its disconnection.

[0065] In some embodiments, a PDU adapter board 31 and a PDU copper busbar 32 are also provided in the second area of ​​the first cavity, and the PDU adapter board 31, the PDU copper busbar 32, and the PDU fuse and PDU relay in the PDU functional unit in the controller body are integrated; the input and output ends of the PDU relay are electrically connected and fixed to the PDU adapter board 31, the PDU copper busbar 32 is connected to the output end of the MSD switch in the controller body, and the high-voltage direct current output by the MSD switch in the controller body is output to the PDU relay through the PDU copper busbar 32; the PDU fuse is installed on the PDU adapter board 31; wherein the PDU fuse includes: fuses of air conditioning modules, fuses of PTC modules, fuses of defrost modules, fuses of DC-DC modules, and fuses of reserved interfaces arranged in sequence. The second area in the first cavity is such as the left area in the first cavity.

[0066] See also Figure 4 and Figure 5 In the example shown, the PDU adapter board 31 is integrated with the PDU copper busbar 32, the PDU fuse 33, and the PDU relay 29. The input and output ends of the PDU relay 29 are electrically connected and fixed to the PDU adapter board 31 by screws. The PDU copper busbar 32 is connected to the output end of the MSD by the copper busbar. The high-voltage direct current output by the MSD is output to each PDU relay 29 through the PDU copper busbar 32. The PDU relay 29 is output to the PDU fuse 33 through the PDU adapter board 31, and the PDU fuse 33 is output to the PDU interface 24. This form of onboard relays and fuses not only saves space, but also reduces the use of distribution harnesses and reduces the cost of a dual-branch six-in-one controller. The main control board 3 is electrically connected to the weak current interface of the PDU relay 29 to control its opening and closing. The PDU fuses 33 are respectively from top to bottom: air conditioning module, first battery heating module, second battery heating module, oil pump motor module, air pump motor module, PTC module, defrost module, DC-DC module, and reserved fuses. The PDU fuses are all fixed to the PDU adapter board 31 by screws. The PDU relays 29 are respectively from top to bottom: air conditioning module, first battery heating module, second battery heating module, main drive pre-charging module, auxiliary drive pre-charging module, auxiliary drive module, TMS module, PTC module, defrost module, and reserved relays. The PDU relays are all fixed to the PDU relay support sheet metal 27 by screws. The PDU relay support sheet metal 27 is fixed to the controller housing 10 by screws. The output end of the main drive pre-charging relay K1 is connected to the pre-charging resistor R2 37 through a wiring harness, and the output end of the pre-charging resistor R2 37 is connected to the positive electrode of the bus capacitor 6. The output end of the auxiliary drive pre-charging relay K5 is electrically connected to the main control board 3, and the main control board 3 outputs to the input end of the oil pump fuse F6.

[0067] In some embodiments, a flow channel cover plate 44 is provided to match the series liquid-cooled heat dissipation flow channel; the flow channel cover plate 44 is welded to the series liquid-cooled heat dissipation flow channel at the heat dissipation area in the shell; in the second cavity, the DC-DC module 16 and the auxiliary drive inverter 17 in the controller body are installed on the flow channel cover plate 44; the auxiliary drive drive board 18 in the controller body is welded to the auxiliary drive inverter 17, the auxiliary drive inverter 17, the auxiliary drive drive board 18, and the auxiliary drive main control board 19 in the controller body are all installed on the inner wall of the shell, and the auxiliary drive drive board 18 is electrically connected to the auxiliary drive main control board 19 through a wiring harness; the high-voltage input interface of the auxiliary drive drive board 18 is electrically connected to the oil pump fuse and the air pump fuse in the controller body through a wiring harness, and the output interface of the auxiliary drive drive board 18 is electrically connected to the auxiliary drive interface 23 in the controller body through a wiring harness. The main control board 3 in the controller body is electrically connected to the weak current interface of the DC-DC module 16 and the weak current interface of the auxiliary drive main control board 19 through a wiring harness; the high voltage input interface of the DC-DC module 16 is electrically connected to the output end of the DC-DC fuse in the controller body through a wiring harness, and the output interface of the DC-DC module 16 is electrically connected to the battery interface in the controller body through a copper busbar;

[0068] Figure 6 The figure is a schematic diagram of the installation structure of the bottom surface of the dual-branch six-in-one controller. Figure 6 As shown, the flow channel cover plate 44 is welded to the flow channel of the shell by friction welding, and the DC-DC module 16 and the auxiliary drive inverter 17 are fixed to the flow channel cover plate 44 and the controller shell 10 by screws to achieve the purpose of heat dissipation. The auxiliary drive drive board 18 is welded to the auxiliary drive inverter 17, and the auxiliary drive inverter 17, the auxiliary drive drive board 18, and the auxiliary drive main control board 19 are all fixed to the controller shell 10 by screws. The main control board 3 is electrically connected to the auxiliary drive main control board 19 and the DC-DC module 16 weak current interface through a wiring harness for power supply and communication. The auxiliary drive drive board 18 and the auxiliary drive main control board 19 are directly electrically connected through a wiring harness for power supply and communication. The high-voltage input interface of the auxiliary drive drive board 18 is electrically connected to the output end of the oil and gas pump fuse through a wiring harness, and its output interface is electrically connected to the auxiliary drive interface 23 through a wiring harness. The high-voltage input interface of the DC-DC module 16 is electrically connected to the output end of the DC-DC fuse through a wiring harness, and the output interface is electrically connected to the battery interface 14 through a copper bus. The DC-DC module 16 can convert high-voltage direct current into low voltage and store it in the battery.

[0069] In some embodiments, a high-voltage input interface, a fast-charging input interface, and a three-phase output interface of the controller body are provided on the first surface of the outside of the shell (such as on the external front of the shell); the high-voltage input interface, the fast-charging input interface, and the three-phase output interface of the controller body are all connected to the power line using a through-hole connector 22, and the through-hole connector 22 is installed on the internal junction box 15 of the shell through a sealed socket.

[0070] Figure 7 The figure below is a schematic diagram of the front installation structure of a dual-branch six-in-one controller. Figure 7 As shown, the high-voltage input, fast-charging input and three-phase output interfaces of the dual-branch six-in-one controller are all connected to the power line using a through-hole connector 22. The through-hole connector 22 is fixed to the junction box 15 through a sealed socket and screws. The interface functions are from left to right: positive of the first battery pack, positive of the second battery pack, positive of the first fast-charging module, positive of the second fast-charging module, negative of the first battery pack, negative of the second battery pack, negative of the first fast-charging module, negative of the second fast-charging module, and U, V, and W three-phase outputs.

[0071] In some embodiments, the MSD interface 25, the battery heating interface 30, the PDU interface 24, and the auxiliary drive interface 23 of the controller body are provided on the second surface of the outside of the shell (such as on the left side of the outside of the shell); the PDU interface 24 includes: an air conditioning interface, a TMS interface, a PTC interface, a defrost interface and a PTC interface arranged in sequence; the auxiliary drive interface 23 includes: an oil pump interface and an air pump interface.

[0072] Figure 8 This is the left view of the dual-branch six-in-one controller. Figure 2 As shown, the left side interface of the dual-branch six-in-one controller includes: MSD 25, battery heating interface 30, PDU interface 24, auxiliary drive interface 23. MSD 25 is a manual maintenance switch with built-in high-voltage fuse and high-voltage interlocking function. It is located in the input main circuit of the battery pack of each branch. Before repairing or removing the controller on the vehicle, the high-voltage circuit can be disconnected by unplugging MSD 25, which can protect the safety of technicians repairing electric vehicles under high-voltage environment or respond to sudden events. The battery heating interface 30 is connected to the battery pack. The functions of the PDU interface 24 from left to right are air conditioning, TMS, PTC, defrosting, and PTC, respectively, and the loads are connected externally. The auxiliary drive interface 23 includes: an oil pump interface and an air pump interface, which are respectively connected to the oil pump motor and the air pump motor. The switch and the negative pole of the interface are electrically connected to the output end of the main negative relay through a wiring harness. The switch and the interface are fixed to the controller housing 10 by screws.

[0073] In some embodiments, a weak current signal interface 4 and a battery interface 14 of the controller body are provided on the third surface of the outside of the shell (such as the right side surface of the outside of the shell), and a water outlet 12 and a water inlet 13 adapted to the series liquid cooling heat dissipation channel are also provided.

[0074] Fig. 9 This is the right side view of the dual-branch six-in-one controller. Fig. 9 As shown, the right side interfaces of the dual-branch six-in-one controller include: a weak current signal interface 4, a water outlet 12, a water inlet 13, and a battery interface 14. The weak current signal interface 4 is externally connected to the vehicle control unit (VCU) of the electric vehicle. The battery interface 14 includes a battery positive electrode interface and a battery negative electrode interface, and is externally connected to a low-voltage battery.

[0075] Fig.10 Figure 1 is a schematic diagram of an isometric view of a dual-branch six-in-one controller. Fig.10 In the isometric view of the dual-branch six-in-one controller shown, the junction box cover 21 is removed to facilitate high-voltage power line wiring. The PDU fuse cover 1 is fixed to the controller top cover 2 by screws, located above the PDU fuse-33. When the fuse is damaged, the PDU fuse cover 1 can be removed to replace the fuse.

[0076] The solution of the utility model, through the shell and control assembly structure, sets the upper and lower cavities for sampling on the internal structure, integrates the five-in-one controller, the battery high-voltage distribution box and the insulation detection unit, which is beneficial to the standardization of batteries by battery manufacturers; adopts a dual-branch solution, including dual input, dual charging, MSD functions, etc., and has the functions of dual input, dual charging, five-in-one controller + battery high-voltage distribution box + insulation detection. The dual-branch six-in-one controller includes main drive function, high-voltage power distribution function, oil pump control function, air pump control function, direct current-direct current (DC-DC) power conversion function, and insulation detection unit. The high-voltage power distribution function includes the vehicle high-voltage distribution box and the battery high-voltage distribution box. The five-in-one controller includes the vehicle high-voltage distribution box, which is integrated into the PDU function unit. The integrated design of the battery high-voltage distribution box and the five-in-one controller is conducive to the standardized design of batteries by battery manufacturers. After integration, battery manufacturers and vehicle manufacturers only need to replace software and match communication protocols. In addition, after integration, the use of connectors is reduced, long-distance leads are reduced, development costs are reduced, and integration is higher. The power distribution function of the dual-branch six-in-one controller is a dual-branch dual-charging power distribution solution. The two branches are connected in parallel and two power battery packs are connected externally. When one of the branches fails, the other branch can continue to supply power to the vehicle, and the vehicle can drive normally. The safety and reliability of the battery system and the vehicle are improved, and the dual-branch dual-fast charging solution has a faster charging speed, which is twice that of the original single-branch solution.

[0077] By adopting the technical solution of the utility model, a five-in-one controller for a vehicle and a high-voltage distribution box for realizing a high-voltage power distribution function are used, and the five-in-one controller, the insulation detection unit and the high-voltage distribution box are integrated, and the high-voltage power distribution function adopts a dual-branch dual-charging and distribution solution, the dual branches are connected in parallel and can be externally connected to two power battery packs, forming a dual-branch six-in-one controller for the vehicle, which is suitable for new energy commercial vehicles; thus, by integrating the five-in-one controller, the insulation detection unit and the high-voltage distribution box, the use of connectors is reduced, and long-distance leads are reduced, which is conducive to improving integration and reducing development costs; by making the high-voltage power distribution function adopt a dual-branch dual-charging and distribution solution, when one of the dual branches fails, the other branch can continue to supply power to the vehicle to ensure normal driving of the vehicle, which is conducive to improving the reliability and safety of the vehicle's battery system and the entire vehicle.

[0078] According to an embodiment of the utility model, a new energy commercial vehicle corresponding to a controller device of the vehicle is also provided. The new energy commercial vehicle may include: the controller device of the vehicle described above.

[0079] Since the processing and functions implemented by the new energy commercial vehicle of this embodiment basically correspond to the embodiments, principles and examples of the vehicle's controller device, for the details not described in this embodiment, please refer to the relevant descriptions in the aforementioned embodiments and will not be repeated here.

[0080] In summary, it is easy for those skilled in the art to understand that, under the premise of no conflict, the above-mentioned advantageous methods can be freely combined and superimposed.

[0081] The above description is only an embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the scope of the claims of the present invention.

Claims

1. A vehicle controller device, characterized in that: include: A housing and a controller body, wherein the controller body is adapted to be arranged in a matching manner with the housing; The controller body includes: a five-in-one controller and other functional units; the five-in-one controller includes: a main drive functional unit, a PDU functional unit, a DC-DC functional unit, an oil pump functional unit and an air pump functional unit; the other functional units include: an insulation detection unit and a battery high-voltage distribution unit; the battery high-voltage distribution unit has a charging and distribution branch; wherein, The five-in-one controller is integrated with the insulation detection unit and the battery high-voltage distribution unit; and / or, In the battery high-voltage power distribution unit, the number of the charging and distribution branches is at least two; at least two of the charging and distribution branches are connected in parallel; Among them, when the five-in-one controller, the battery high-voltage distribution unit and the insulation detection unit are integrated, and the number of the charging and distribution branches is at least two, a dual-branch six-in-one integrated controller is obtained.

2. The vehicle controller device according to claim 1, characterized in that: In the battery high-voltage power distribution unit, at least two of the charging and distribution branches include a first charging and distribution branch and a second charging and distribution branch; the first charging and distribution branch and the second charging and distribution branch have the same structure; Among them, the first charging and distribution branch includes: a first main positive branch connected to an external first battery pack, a first main negative branch, and a first fast charging branch; a first MSD switch is arranged in the first main positive branch, and the positive electrode of the external first battery pack is connected to the main circuit high-voltage positive electrode of the vehicle's controller device after passing through the first MSD switch; a first CAN current sensor is arranged in the first main negative branch, and the negative electrode of the external first battery pack is connected to the main circuit high-voltage negative electrode of the vehicle's controller device after passing through the first CAN current sensor; the insulation detection unit is arranged between the main circuit high-voltage positive electrode and the main circuit high-voltage negative electrode, and the insulation detection unit is located on the rear side of the first main negative branch; a main negative relay is arranged on the main circuit high-voltage negative electrode, and the main negative relay is located on the rear side of the insulation detection unit and on the front side of the first fast charging branch.

3. The vehicle controller device according to claim 2, characterized in that: A first positive branch relay and a first negative branch relay are provided in the first fast charging branch; wherein, The positive pole of the first fast charging branch is connected to the high-voltage positive pole of the main circuit through the first positive branch relay, and the negative pole of the first fast charging branch is connected to the high-voltage negative pole of the main circuit through the first negative branch relay.

4. The vehicle controller device according to any one of claims 1 to 3, characterized in that: The PDU functional unit in the five-in-one controller includes: an air conditioning control interface, a battery heating interface, a PTC interface and a defrosting interface; wherein, adapted to each interface in the PDU functional unit in the five-in-one controller, an interface relay and an interface fuse corresponding to each interface are provided; the main circuit high-voltage positive electrode of the vehicle's controller device is connected to the positive electrode of each interface after passing through the interface relay and the interface fuse corresponding to each interface; the negative electrode of each interface is connected to the main circuit high-voltage negative electrode of the vehicle's controller device; The PDU functional unit in the dual-branch six-in-one integrated controller includes the PDU functional unit in the five-in-one controller, and also includes a TMS control interface and a reserved interface; wherein a TMS relay is provided to match the TMS control interface; the main circuit high-voltage positive electrode of the vehicle's controller device is connected to the positive electrode of the TMS control interface after passing through the TMS relay; the negative electrode of the TMS control interface is connected to the main circuit high-voltage negative electrode of the vehicle's controller device; A reserved relay and a reserved fuse are provided to match the reserved interface; the high-voltage positive pole of the main circuit of the vehicle's controller device is connected to the positive pole of the reserved interface after passing through the reserved relay and the reserved fuse; the negative pole of the reserved interface is connected to the high-voltage negative pole of the main circuit.

5. The vehicle controller device according to claim 4, characterized in that: The number of the battery heating interfaces is the same as the number of battery packs connected to at least two of the charging and distribution branches; when the at least two charging and distribution branches are two charging and distribution branches, the battery heating interfaces are the first battery heating interface and the second battery heating interface; a battery heating relay, a first heating fuse and a second heating fuse are provided to match the first battery heating interface and the second battery heating interface; the high-voltage positive pole of the main circuit of the vehicle's controller device is divided into two paths after passing through the battery heating relay: one path is connected to the positive pole of the first battery heating interface after passing through the first heating fuse, and the other path is connected to the positive pole of the second battery heating interface after passing through the second heating fuse; the negative pole of the first battery heating interface is connected to the high-voltage negative pole of the main circuit of the vehicle's controller device, and the negative pole of the second battery heating interface is connected to the high-voltage negative pole of the main circuit of the vehicle's controller device.

6. The vehicle controller device according to any one of claims 1 to 3 and 5, characterized in that: in, The DC-DC functional unit in the five-in-one controller includes: a DC-DC module and a charging fuse; wherein the high-voltage positive electrode of the main circuit of the vehicle's controller device is connected to the input end of the DC-DC module after passing through the charging fuse; the first connection end of the output end of the DC-DC module is connected to the first connection end of the battery of the vehicle, the second connection end of the output end of the DC-DC module is connected to the second connection end of the battery of the vehicle, and the ground end of the DC-DC module is connected to the high-voltage negative electrode of the main circuit of the vehicle's controller device; and / or, The main drive functional unit in the five-in-one controller includes: a main drive fuse, a main drive pre-charging relay, a main drive pre-charging resistor and a main drive relay; wherein the high-voltage positive pole of the main circuit of the vehicle controller device is divided into a main drive pre-charging circuit and a main drive main circuit after passing through the main drive fuse, and the main drive pre-charging circuit and the main drive main circuit are connected in parallel and then output to the inverter in the motor controller of the vehicle; the main drive pre-charging relay and the main drive pre-charging resistor are connected in series in the main drive pre-charging circuit, and the main drive relay is arranged in the main drive main circuit; and / or, An auxiliary drive function unit is provided to match the oil pump function unit and the air pump function unit in the five-in-one controller; the auxiliary drive function unit includes: an auxiliary drive relay, an auxiliary drive pre-charging relay and an auxiliary drive pre-charging resistor, the auxiliary drive relay is arranged in the auxiliary drive main circuit, and the auxiliary drive pre-charging relay and the auxiliary drive pre-charging resistor are connected in series in the auxiliary drive pre-charging circuit; the oil pump function unit includes an oil pump fuse, an EPS module and an oil pump motor interface, and the air pump function unit includes an air pump fuse, an AIR module and an air pump motor interface; wherein, the high-voltage positive pole of the main circuit of the vehicle's controller device is divided into two paths after passing through the auxiliary drive main circuit and the auxiliary drive pre-charging circuit connected in parallel: one path is connected to the oil pump motor interface after passing through the oil pump fuse and the EPS module, and the negative pole of the EPS module is connected to the high-voltage negative pole of the main circuit of the vehicle's controller device; the other path is connected to the air pump motor interface after passing through the air pump fuse and the AIR module, and the negative pole of the AIR module is connected to the high-voltage negative pole of the main circuit of the vehicle's controller device.

7. The vehicle controller device according to any one of claims 1 to 3 and 5, characterized in that: The housing is made of ADC12 material by high pressure casting, and the accommodating space inside the housing is divided into a first cavity, a second cavity and a heat dissipation area; wherein, The first cavity and the second cavity are arranged vertically, and the controller body is disposed in the first cavity and the second cavity; The heat dissipation area is located between the first cavity and the second cavity, and the heat dissipation area is provided with a series liquid cooling heat dissipation channel for dissipating the heat of the heating element in the controller body.

8. The vehicle controller device according to claim 7, characterized in that: in, A sheet metal part (5) is arranged in a first area in the first cavity, and a main control board (3) and a bus capacitor (6) in the controller body are mounted on the sheet metal part (5); the functional modules on the main control board (3) include: at least one of a power module, a communication module, a minimum system, a main drive control module, a PDU relay control module, a current sampling circuit, a voltage sampling circuit, an insulation detection unit and a high-voltage interlocking module in the controller body; the bus capacitor (6) is connected to an inverter in a motor controller in a controller device of the vehicle; and / or, A PDU adapter board (31) and a PDU copper busbar (32) are also provided in the second area of ​​the first cavity. The PDU adapter board (31), the PDU copper busbar (32), and the PDU fuse and the PDU relay in the PDU functional unit in the controller body are integrated; the input and output ends of the PDU relay are electrically connected and fixed to the PDU adapter board (31), and the PDU copper busbar (32) is connected to the output end of the MSD switch in the controller body; the PDU fuse is installed on the PDU adapter board (31); wherein the PDU fuse includes: a fuse of an air conditioning module, a fuse of a PTC module, a fuse of a defrost module, a fuse of a DC-DC module, and a fuse of a reserved interface arranged in sequence.

9. The vehicle controller device according to claim 7, characterized in that: in, A flow channel cover plate (44) is provided to match the series-type liquid-cooled heat dissipation flow channel; the flow channel cover plate (44) is welded to the series-type liquid-cooled heat dissipation flow channel at the heat dissipation area in the shell; in the second cavity, the DC-DC module (16) and the auxiliary drive inverter (17) in the controller body are mounted on the flow channel cover plate (44); the auxiliary drive drive board (18) in the controller body is welded to the auxiliary drive inverter (17), the auxiliary drive inverter (17), the auxiliary drive drive board (18), and the auxiliary drive main control board (19) in the controller body are all mounted on the inner wall of the shell, and the auxiliary drive drive board (18) is electrically connected to the auxiliary drive main control board (19) through a wiring harness; the main control board (3) in the controller body is electrically connected to the weak current interface of the DC-DC module (16) and the weak current interface of the auxiliary drive main control board (19) through a wiring harness; and / or, A high-voltage input interface, a fast-charging input interface, and a three-phase output interface of the controller body are provided on the first surface of the exterior of the housing; the high-voltage input interface, the fast-charging input interface, and the three-phase output interface of the controller body are all connected to the power line using a through-hole connector (22), and the through-hole connector (22) is installed on the internal junction box (15) of the housing through a sealed socket; and / or, An MSD interface (25), a battery heating interface (30), a PDU interface (24), and an auxiliary drive interface (23) of the controller body are arranged on the second surface outside the housing; the PDU interface (24) includes: an air conditioning interface, a TMS interface, a PTC interface, a defrost interface, and a PTC interface arranged in sequence; the auxiliary drive interface (23) includes: an oil pump interface and an air pump interface; and / or, A weak-electric signal interface (4) and a battery interface (14) of the controller body are provided on the third surface of the exterior of the shell, and a water outlet (12) and a water inlet (13) adapted to the series-connected liquid-cooling heat dissipation channel are also provided.

10. A new energy commercial vehicle, characterized in that: include: A controller device for a vehicle as claimed in any one of claims 1 to 9.

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