Integrated passenger car high-voltage power distribution structure and passenger car

Abstract

The utility model relates to an integrated passenger car high-voltage power distribution structure and a passenger car. The integrated passenger car high-voltage power distribution structure comprises a battery module interface, a battery output interface and a BMS control module. And the battery module interface is connected in parallel with the battery pack interface through a high-voltage lead so as to realize electrical connection of the battery module. And the battery output interface comprises a plurality of direct current or alternating current output interfaces and is used for supplying power to external electric equipment. The output interfaces are connected through a high-voltage interlocking circuit, and the high-voltage interlocking circuit comprises a state detection wire which is used for detecting the input and output state of each interface and transmitting state information to the BMS control module. The BMS control module is responsible for the controller to output signals so as to drive switches of a plurality of direct-current or alternating-current interfaces, so that complete control over high-voltage interlocking is achieved, and correct interaction between a high-voltage system and other vehicle systems is ensured. Meanwhile, due to the high integration level, the system complexity is reduced, the installation space requirement is reduced, and the maintainability is enhanced.

Description

Technical Field

[0001] This application belongs to the field of high-voltage power distribution and battery control systems in the field of new energy buses, specifically covering the power battery controller (BMS), power battery junction box and vehicle high-voltage distribution box. Background Art

[0002] At present, the bus industry usually uses control boxes (including BMS) and corresponding battery junction boxes provided by power battery manufacturers to complete the battery system's SOC (State of Charge), battery cell balancing, battery temperature management, as well as the distribution of charging, discharging and battery heating, and line protection. In addition, the power distribution function (such as high-voltage devices such as drive, air conditioning, steering pump, etc.) and line protection are realized through the high-voltage distribution box. However, the current system has a high degree of component separation, and there are multiple interconnected wiring harnesses, which take up a large space and are costly. Different components need to work together, involving more communication control, which makes the entire system appear more complicated.

[0003] Due to the existence of the above-mentioned problems, it is necessary to improve the high-voltage power distribution and battery control system of new energy buses, provide more efficient, compact and economical solutions through integrated simplified wiring and optimized control, and simplify the communication mechanism to reduce the number of wiring harness connections. Utility Model Content

[0004] The goal of this application is to solve multiple problems in the current new energy bus system, including component separation, complex interconnection harnesses, large space occupation, and high cost, by integrating the power battery control box (BMS), battery junction box, and vehicle high-voltage distribution box.

[0005] The objectives of this application also include that the high-voltage distribution box provides an integrated oil pump power interface, an air pump power interface, and a low-voltage DC power interface.

[0006] The objective of the present application also includes providing a high-voltage interlock circuit for the battery output interface, thereby achieving complete control of the high-voltage interlock and ensuring the correct interaction of the high-voltage system with other vehicle systems.

[0007] The technical solution of this application is to use a BMS with a multi-channel output control function as the main control component to complete the management tasks of the battery system's SOC (State of Charge), battery cell balancing, battery temperature, etc. At the same time, through the control and monitoring of multiple outputs, the high-voltage power distribution and line protection functions of the entire vehicle are realized. This solution, with the help of the versatility and maturity of the BMS, provides a more simplified and reliable battery management and high-voltage power distribution solution for new energy bus systems.

[0008] Specifically, the present application discloses an integrated bus high-voltage power distribution structure including a battery module interface, a battery output interface, a BMS control module, etc. The battery module interface includes a battery pack interface, a battery thermal management interface, a charging interface, and a communication interface. The BMS control module includes a parameter detection unit and a communication terminal for detecting battery parameters and electrically connecting to the communication interface. The high-voltage wire is electrically connected to each interface in the battery module interface and the battery output interface through a switch. Among them, the battery pack interface is connected in parallel with a pre-charging circuit, and the pre-charging circuit includes a switch and a resistor in series. A current sensor is electrically connected to the high-voltage wire, and the current sensor is electrically connected to the current detection interface of the BMS detection module. The BMS module includes a single cell balancing module, a charge and discharge management module, a temperature management module, and an insulation detection module. The high-voltage wire of each interface in the battery output interface is connected in series with a fuse. The battery output interface also includes a diagnostic interface, which is electrically connected to the BMS module. Finally, the entire structure can be applied to buses.

[0009] Furthermore, the battery output interface includes multiple DC or AC output interfaces; the multiple DC or AC interfaces are connected to a high-voltage interlocking circuit, and the high-voltage interlocking circuit includes a status detection wire. The status detection wire is used to detect the input and output status of each interface, and transmit the input and output status to the controller BMS control module through the wire. The BMS control module controller output signal is used to drive the switches of the multiple DC or AC interfaces to achieve complete high-voltage interlocking.

[0010] The advancement of this application over the prior art is:

[0011] The system has complete battery management functions, including SOC, cell balancing, charge and discharge management, and temperature management, to ensure efficient operation of the battery system.

[0012] The system has insulation detection function to improve the safety and stability of high-voltage circuits and reduce the risk of potential failures.

[0013] The pre-charge function of the discharge circuit is integrated to effectively manage energy release and improve system energy efficiency and performance.

[0014] It realizes the distribution and protection of high-voltage electricity, ensures the reasonable distribution of electricity among various equipment, and provides an effective protection mechanism.

[0015] The high integration reduces system complexity and manufacturing costs, significantly reducing the installation space requirements on the vehicle and improving space efficiency and design flexibility.

[0016] The high degree of system integration simplifies the interaction between modules and enhances the maintainability and synergy of the overall system.

[0017] The BMS control module can control the high-voltage interlocking of different interfaces, realize high-voltage interlocking under the premise of high integration, and improve system safety.

[0018] In short, through these advantages, the system provides a reliable, efficient and economical comprehensive solution for new energy buses, meeting the multi-faceted needs of the vehicle system. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is a partial schematic diagram of the integrated bus high-voltage distribution structure of Example 1.

[0020] Figure 2 It is a partial schematic diagram of the integrated bus high-voltage distribution structure of Example 1.

[0021] Figure 3 It is a partial schematic diagram of the integrated bus high-voltage distribution structure of the second embodiment. DETAILED DESCRIPTION

[0022] In order to more effectively help those skilled in the art understand the technical solution of the present application, the implementation scheme will be described in detail below and illustrated in conjunction with the accompanying drawings. To provide more in-depth explanations and examples to ensure that those skilled in the art have a more comprehensive and clear understanding of the technical content of the present application. It should be emphasized that although detailed explanations and examples are provided, this does not mean that any limitation is made to the scope of protection of the present application. Ultimately, the scope of protection of the present application shall still be subject to the limitations in the claims.

[0023] In addition, this application is a further improvement based on the applicant's prior patent (application number CN202421829062.9), and its entire content is hereby introduced into this application as a part of this application. Embodiment 1

[0024] It should be noted that Figure 1 and Figure 2 These are schematic diagrams of local module structures. Components and structures that are not related to the core idea of ​​the invention of this application are omitted in these figures. However, these omitted parts do not affect the ability of those skilled in the art to implement a complete circuit structure based on the technical solution disclosed in this application and the prior art. Therefore, Figure 1 and Figure 2 The disclosure is clear and complete, and is sufficient for technicians to understand and implement the technical solutions of this application.

[0025] For details, please refer to Figure 1 shown.

[0026] An integrated bus high-voltage power distribution structure is contained in a housing 100. The high-voltage power distribution structure includes a battery module interface 200, a battery output interface 300, and a BMS control module. The battery module interface 200 is connected in parallel to a battery pack interface 201, a battery thermal management interface 202, a charging interface 203, and a communication interface 204 via a high-voltage wire 205 (a wire with a larger line width in the figure). The BMS control module 400 includes a parameter detection unit 401, which is electrically connected to each interface of the battery module interface through an electrical connection, and is used to detect the parameters of the battery. At the same time, the BMS control module 400 also includes communication terminals, which are connected to the communication interface 204.

[0027] Optionally, the battery module interface 200 and the battery output interface 300 comply with common industry standards or national standards, including but not limited to the Chinese national standard GB / T, the Japanese standard CHAdeMO, the combined charging system standard CCS, and the IEC standard formulated by the International Electrotechnical Commission.

[0028] The battery pack interface 201 is a physical connection point of the battery system, and is electrically connected to the battery cells in the battery pack through the high-voltage wire 205. It plays the role of transmitting electric energy, and transmits the electric energy generated by the battery cells to the entire battery system.

[0029] The battery thermal management interface 202 is used to electrically connect the thermal management module in the battery system. The function of this interface is to monitor and regulate the temperature of the battery, ensure that the battery operates within a suitable temperature range, and improve the performance and life of the battery.

[0030] The charging interface 203 is where the battery system is electrically connected to an external power source. Through the charging interface 203, the battery can receive electrical energy from the external power source for charging.

[0031] The communication interface 204 is used to electrically connect to the communication module 402 in the battery management system (BMS). This interface enables the battery system to communicate with the overall electrical system of the vehicle to monitor and manage information such as battery status, power, temperature, etc. The communication interface may also exchange data with external devices or networks to achieve remote monitoring and diagnosis.

[0032] Preferably, the parameters detected by the BMS control module 400 include but are not limited to: battery voltage, current, temperature, charge state, health state, cell voltage balance, insulation resistance, and battery internal resistance, etc. By monitoring the electrical characteristics and environmental conditions of the battery, the BMS control module 400 ensures safe operation and performance optimization of the battery system.

[0033] The circuit structure in the parameter detection module of the BMS control module 400 takes the voltage detection module 403 as an example. The voltage detection module is a key hardware component of the BMS chip. This module is responsible for processing the voltage data detected from the battery cell or battery pack, and digitizing it and passing it to the execution module in the BMS control module 400. The voltage detection module 403 is electrically connected to the battery pack interface 201 and the battery thermal management interface 202 in parallel with the high-voltage wire to receive the voltage signal in the battery system. This structure ensures that the BMS control module 400 can obtain the voltage information of the battery in real time, providing the necessary data for monitoring and management of the battery status.

[0034] The BMS control module 400 also includes multiple sub-modules, including a SOC module 403, a cell balancing module 404, a charge and discharge management module 405, a temperature management module 406, and an insulation detection module 407. These modules can be software modules of a general-purpose processor or hardware modules such as FPGA, ASIC, etc.

[0035] The SOC module 403 is responsible for estimating the battery's state of charge, that is, the percentage of the battery's current stored energy relative to its maximum energy capacity. By accurately estimating the SOC, the BMS control module 400 can provide real-time information on the remaining available energy in the battery, helping the driver to better manage the use of the battery.

[0036] The cell balancing module 404 monitors and adjusts the voltage difference between the individual battery cells in the battery pack. By performing balancing operations, such as discharging or charging the battery cells, the charge level of each cell in the battery pack is ensured to be consistent, thereby improving the life and performance of the battery pack.

[0037] The charge and discharge management module 405 is responsible for controlling the charging and discharging process of the battery, including functions such as charging control, discharging control, charging cut-off protection, and over-discharge protection, to ensure that the battery operates within a safe and efficient range.

[0038] The temperature management module 406 monitors the temperature of the battery pack and takes measures to ensure that the battery operates within a suitable temperature range, which may include temperature sensors, heat dissipation control and temperature regulation devices to prevent overheating or overcooling from affecting battery performance and safety.

[0039] The insulation detection module 407 is used to monitor the insulation status of the battery system. It detects whether there is an insulation fault between the battery system and the vehicle structure or other electrical components to prevent short circuits and improve the safety of the battery system.

[0040] These submodules of the BMS control module 400 work together to ensure that the battery system maintains safe, stable and efficient operation under various operating conditions. The design goal of the BMS control module 400 is to comprehensively monitor and manage all aspects of the battery to improve the performance, life and overall reliability of the battery system.

[0041] Furthermore, the high voltage wire 205 is electrically connected to each of the battery module interface 200 and the battery output interface 300 through a switch. The switch is a relay controlled by the BMS module.

[0042] Furthermore, the battery pack interface 201 is connected in parallel with a pre-charging circuit 207, and the pre-charging circuit 207 includes a switch 206 and a resistor 208 connected in series. The pre-charging circuit 207 plays a role when the high-voltage battery system is electrically connected, and gradually increases the voltage at the power end, thereby reducing the voltage difference between the two ends, effectively reducing the current impact, reducing the risk of arc generation, and providing a smooth start-up process. It helps to protect the battery and related electronic components and improve the overall safety and stability of the battery system.

[0043] Furthermore, the high-voltage wire 205 is electrically connected to a current sensor 209, and the current sensor 209 is electrically connected to a current detection interface of a BMS detection module. The current sensor 209 is an inductive current sensor 209, and its structure generally includes a magnetic core and a winding. The magnetic core is used to concentrate and guide the magnetic field generated by the current, and the magnetic core includes silicon steel sheets or ferrite. The winding is a coil wrapped around the magnetic core. When the current passes through the high-voltage wire 205, a magnetic field is generated in the magnetic core, and the magnetic field generates a voltage signal in the winding. The BMS detects the current signal on the high-voltage wire by detecting the voltage signal.

[0044] During operation, the high voltage of the power battery first passes through the MSD (manual disconnect) and the pre-charging circuit 208 controlled by the BMS to prepare for the power consumption of the vehicle. Subsequently, the BMS control module 400 controls the thermal management relay to power the battery thermal system to ensure operation within a suitable temperature range. The charging function is realized by the BMS control module 400 controlling the charging relay to charge the battery safely and effectively.

[0045] The internal network of the battery system is responsible for collecting the voltage and temperature information in the battery pack, and obtaining the current signal through the internal current sensor 209. These data are summarized in the BMS control module 400 to perform conventional BMS control module 400 functions such as estimating SOC (state of charge), charge and discharge management of the power battery, and passive balancing of each battery cell. In addition, the system also includes corresponding voltage, current detection circuits and insulation detection circuits to achieve some auxiliary functions and enhance the performance and safety of the overall battery system. Through the above control and monitoring means, the distribution system can effectively manage the power battery and ensure the reliable operation of the vehicle power system.

[0046] Reference Figure 2 As shown, the battery output interface is connected in parallel through high-voltage wires to the drive motor interface 421, the vehicle charging interface 422, the DC / DC converter interface 424, the air conditioning interface 426 and the auxiliary power interface 428. This structure integrates battery management and high-voltage output functions.

[0047] The high-voltage wires are connected in parallel to the drive motor interface 421, the vehicle charging interface 422, the DC / DC converter interface 424, the air conditioning interface 426, and the auxiliary power interface 428. The battery output interface has become a dedicated interface for each high voltage and the corresponding high-voltage interlock circuit wire 429. The function of the high-voltage interlock circuit is mainly to ensure the safe operation of the high-voltage system. By achieving safe power-off, preventing misoperation, equipment protection, operation sequence control and system integration, the high-voltage interlock circuit effectively prevents potential dangerous situations and ensures the reliability and safety of the high-voltage system. This circuit design is designed to prevent unsafe operations, provide emergency power-off functions, and integrate with the entire system to ensure the stability and safe operation of the high-voltage system under various operating and environmental conditions.

[0048] At the same time, each branch line is protected by equipping it with a high-voltage fuse (labeled F1-F6) of appropriate specifications. The high-voltage wire of each interface in the battery output interface is connected in series with a fuse (labeled F1-F6). The fuse is used to conduct current in the circuit, but when the current exceeds its rated value, the fuse will disconnect the circuit and prevent the current from continuing to flow, thus playing the role of overload protection.

[0049] The battery output interface includes a diagnostic interface 410, which is electrically connected to the BMS control module 400. The diagnostic interface 410 allows for electrical connection of diagnostic equipment, through which the state of the battery system and the working conditions of each part can be obtained. By monitoring and analyzing the information of the diagnostic interface, possible faults or abnormalities in the battery system can be detected in a timely manner, facilitating fault diagnosis and repair.

[0050] Preferably, the housing 100 is used for protection and isolation, and is made of high temperature resistant and corrosion resistant metal materials with an insulating layer inside some parts. Insulation is ensured by spatial distance, housing equipotential connection and insulation detection. The housing 100 has a seal that effectively isolates external environmental pollution such as dust and moisture to ensure the normal operation of internal electrical components. The housing is designed with a heat dissipation structure, such as a heat sink and a heat sink, to maintain an appropriate temperature of the system.

[0051] Preferably, the housing 100 is modularly designed to make components easier to install, replace and maintain. The safety lock mechanism ensures that only authorized personnel can open the housing, preventing unauthorized personnel from accessing electrical components, and improving the operational safety of the system.

[0052] Preferably, the housing 100 has identification and indication functions to help users and maintenance personnel understand the functions and states of different parts.

[0053] Preferably, the housing 100 has electromagnetic compatibility and adopts a shielding design to reduce electromagnetic interference.

[0054] The progress of this embodiment over the prior art is mainly reflected in the following aspects: First, the system has comprehensive battery management functions, including SOC, cell balancing, charge and discharge management, and temperature management, etc., to ensure efficient and stable operation of the battery system; second, the system has an insulation detection function, which improves the safety and stability of the high-voltage circuit and reduces the potential risk of failure; third, the system integrates the pre-charging function of the discharge circuit, effectively manages energy release, and improves the energy efficiency and performance of the system; in addition, the system realizes the distribution and protection of high-voltage electricity consumption, ensures the reasonable distribution of electricity among various devices, and provides an effective protection mechanism; finally, the high degree of integration reduces the complexity of the system, significantly reduces the installation space requirements on the whole vehicle, improves space efficiency and design flexibility, simplifies the interaction between modules, and enhances the maintainability and coordination of the overall system. Embodiment 2

[0055] This embodiment adds multiple low-voltage DC output interfaces and AC output interfaces on the basis of the first embodiment, wherein the interfaces are used to supply power to external electrical equipment.

[0056] Optionally, the interface of this embodiment can coexist with the interface described in the second embodiment, and the high-voltage wires of the two can be connected in parallel, but the power output state can be controlled independently.

[0057] Reference Figure 3As shown, the interface includes a drive motor interface 431, which is electrically connected to a pre-charging circuit 439 through a high-voltage fuse F1. The pre-charging circuit 439 gradually increases the voltage in the high-voltage battery system to a safe level before the motor drive interface 431 is started, so as to protect the motor drive system and other related electrical equipment from sudden high-voltage current shocks. The pre-charge voltage gradually increases to a safe level, and the pre-charging circuit 439 is closed through a relay, allowing the motor drive to start and run normally.

[0058] The vehicle-mounted charging interface 432 is also included, and the vehicle-mounted charging interface 432 is used to electrically connect to the vehicle-mounted charger, and is electrically connected to the ground power AC grid through the vehicle-mounted charger. When charging, when the vehicle-mounted charging interface 432 is electrically connected to the vehicle-mounted charger, the vehicle-mounted charger will send a charging instruction to the charging management system (BMS), and then the charging management system will control the charging process and transmit electrical energy to the high-voltage battery of the electric vehicle.

[0059] It also includes an air conditioning interface 433, which is a high-voltage electrical output interface. The air conditioning interface 433 is directly electrically connected to the high-voltage wire through a high-voltage fuse F3. The high-voltage air conditioning system is more efficient than the traditional low-voltage system because it uses thinner wires to reduce system load and energy loss, thereby improving the overall system efficiency.

[0060] It also includes an oil pump power interface 434 and an air pump power interface 435. The oil pump is used to provide hydraulic power, such as providing hydraulic oil power for auxiliary steering system. The air pump is usually used for the power of pneumatic brake system, air suspension and door to ensure the control and braking performance of new energy buses.

[0061] Among them, the oil pump and the air pump are powered by high-voltage three-phase electricity. Since the oil pump or the air pump requires high power and large flow output, the use of high-voltage three-phase electricity can provide better performance and efficiency.

[0062] It also includes a DC / AC unified conversion module 440, which includes a first DC / AC conversion module 441, a second DC / AC conversion module 442, and a DC / DC conversion module 443. The unified conversion module includes a single input interface 450, through which the unified conversion module 440 directly uses the high voltage electricity output by the battery as a power source. The unified conversion module 440 converts the three-phase electricity output to the oil pump power interface 434, the three-phase electricity output to the air pump power interface 435, and the direct current output to the low-voltage DC power interface 436 according to different requirements.

[0063] It also includes a backup interface 437. The backup interface 437 on the high-voltage distribution box provides an additional connection point for expanding functions, connecting backup equipment, performing maintenance and repair, and collecting data.

[0064] In addition, it also includes a drive motor interface 431 and a vehicle charging interface 432 that are the same as those in Example 2, which will not be described in detail here.

[0065] The above-mentioned drive motor interface 431, vehicle charging interface 432, air conditioning interface 433, oil pump power interface 434, and air pump power interface 435 are all electrically connected to the high-voltage interlocking circuit. The high-voltage interlocking circuit can ensure the correct interaction between the high-voltage system and other vehicle systems, and prevent the high-voltage system failure from affecting other systems. Prevent the risk of failure or electric shock caused by improper connection between the vehicle charging interface, air conditioning interface, oil pump power interface, and air pump power interface.

[0066] The high-voltage interlock circuit includes a status detection wire 438, which is used to detect the input and output status of each interface and transmit the input and output status to the controller (which can be a BMS control module) through the wire. The controller uses control logic, through programming or hardware, to ensure that interlock operations are performed under specific conditions, such as prohibiting the start of the high-voltage system when it is not connected normally.

[0067] The controller output signal is used to drive the switch of the interface, usually a relay, and the control action of the controller is executed through the relay to achieve a complete high-voltage interlocking function.

[0068] The high-voltage interlock circuit can prevent the failure of one high-voltage interface system from affecting other systems, reducing the risk of electric shock and the possibility of equipment damage. By detecting the connection status of each interface, it can also ensure that the high-voltage system is allowed to start only when it is correctly connected, preventing incorrect operation.

[0069] When the system starts, the high-voltage interlock circuit ensures that the current rises smoothly and gradually to a safe level, preventing sudden high-voltage current shocks, thereby protecting the motor drive system and other high-voltage equipment.

[0070] The high integration of the high-voltage interlocking function system simplifies the interaction between modules, enhances the maintainability and coordination of the overall system, and reduces the wiring harnesses used for communication.

Claims

1. Integrated bus high voltage distribution structure, characterized by: include: Battery module interface, battery output interface and BMS control module; The battery module interface includes a battery pack interface connected in parallel via a high voltage conductor; The battery output interface includes a plurality of DC or AC output interfaces; The plurality of DC or AC interfaces are electrically connected to a high-voltage interlock circuit, the high-voltage interlock circuit comprises a state detection wire, and the state detection wire is electrically connected to the plurality of DC or AC output interfaces to monitor input and output states; The BMS control module is used to drive the switches of the multiple DC or AC interfaces to achieve complete high-voltage interlocking.

2. The integrated bus high voltage distribution structure according to claim 1 is characterized in that: It also includes a DC / AC unified conversion module, which includes a single input interface, and the input interface is electrically connected to the high-voltage wire.

3. The integrated bus high voltage power distribution structure according to claim 2 is characterized in that: The DC / AC unified conversion module includes a first DC / AC conversion module, a second DC / AC conversion module, and a DC / DC conversion module; the multiple DC or AC interfaces include an oil pump power interface, an air pump power interface, and a low-voltage DC power interface; the output end of the first DC / AC conversion module is electrically connected to the oil pump power interface, the output end of the second DC / AC conversion module is electrically connected to the air pump power interface, and the output end of the DC / DC conversion module is electrically connected to the low-voltage DC power interface.

4. The integrated bus high voltage distribution structure according to claim 3 is characterized in that: The battery output interface also includes a drive motor interface electrically connected to the high-voltage wire, a pre-charging circuit is connected in series to the high-voltage wire, the drive motor interface is electrically connected to the pre-charging circuit, and the pre-charging circuit includes a switch and a resistor in series.

5. The integrated bus high voltage distribution structure according to claim 2 is characterized in that: The high voltage wire of each battery output interface is connected in series with a fuse.

6. The integrated bus high voltage power distribution structure according to claim 1 is characterized in that: Also includes: Battery thermal management interface, charging interface and communication interface; The BMS control module includes a parameter detection unit, which is electrically connected to each interface of the battery module interface to detect the parameters of the battery; The BMS control module includes a communication terminal, and the communication terminal is electrically connected to the communication interface; The battery output interface includes a drive motor interface, a vehicle charging interface, a DC / DC converter interface, an air conditioning interface, and an auxiliary power supply interface connected in parallel through the high-voltage wire.

7. The integrated bus high voltage distribution structure according to claim 1 is characterized in that: The BMS control module includes a monomer balancing module, a charge and discharge management module, a temperature management module and an insulation detection module.

8. A passenger car, characterized in that: It comprises the integrated bus high-voltage power distribution structure as described in any one of claims 1-7.

Images