Platform BDU and battery pack

Abstract

The utility model relates to the technical field of new energy automobile batteries, in particular to a platform BDU and a battery pack, the platform BDU comprises a lower shell and an upper shell cover used for covering the lower shell, the lower shell is provided with a first installation area, a second installation area and a third installation area from left to right, the first installation area is provided with a current sensor, a main fuse, a pre-charging relay and a pre-charging resistor, and the second installation area is provided with a second fuse. The second installation area is provided with a main positive relay and a fast charging relay, the fast charging relay and the main positive relay are arranged in parallel, the pre-charging relay and the pre-charging resistor are connected in series and then connected with the two ends of the main positive relay, and the third installation area is provided with a main negative relay and a diverter; the current sensor, the main fuse and the main positive relay are sequentially connected in series through a copper bar and a wire to form a main positive loop, and the diverter and the main negative relay are connected in series to form a main negative loop. According to the utility model, the development number of BDU molds can be reduced, the development cost of battery pack BDU products is reduced, the development cycle of the BDU products is shortened, and the generality of the BDU products is improved.

Description

Technical Field

[0001] The utility model relates to the technical field of new energy vehicle batteries, and specifically relates to a platformized BDU and a battery pack. Background Technique

[0002] New energy vehicles generally include battery electric vehicles (BEV), plug-in hybrid electric vehicles (PHEV), and extended-range electric vehicles (EREV). One of the core components of these vehicle types is the battery pack, which is the main device for storing electrical energy and provides power for the vehicle's electric motor. The BDU (Battery Disconnect Unit), the battery disconnect unit, is an important part of the battery pack and is mainly responsible for controlling and monitoring the connection and disconnection of the high-voltage circuit. It is the "bridge" connecting the battery pack and the vehicle electrical system. Currently, in the field of new energy battery packs, due to the different customer requirements, there are different BDU design schemes for different customers; there are many types of BDU, resulting in waste of resources, high development costs, and long product R & D cycles.

[0003] Based on this, the present application provides a platformized BDU and a battery pack, aiming to reduce the number of BDU mold developments, reduce the development costs of the battery pack BDU products and shorten the BDU product development cycle, improve the universality of the BDU products, and at the same time enhance the product integration and platformized design concept, and improve the product R & D level. Content of the Utility Model

[0004] The utility model provides a platformized BDU and a battery pack, which can reduce the number of BDU mold developments, reduce the development costs of the battery pack BDU products and shorten the BDU product development cycle, and improve the universality of the BDU products.

[0005] The present application provides the following technical solutions:

[0006] A platformized BDU includes a lower housing and an upper housing cover for covering the lower housing. The lower housing is provided with a first installation area, a second installation area, and a third installation area from left to right. The first installation area is provided with a current sensor, a main fuse, a pre-charge relay, and a pre-charge resistor. The second installation area is provided with a main positive relay and a fast charge relay. The fast charge relay is arranged in parallel with the main positive relay. The pre-charge relay and the pre-charge resistor are connected in series and then connected to both ends of the main positive relay. The third installation area is provided with a main negative relay and a shunt; the current sensor, the main fuse, and the main positive relay are sequentially connected in series through a copper bar and a wire to form a main positive circuit, and the shunt and the main negative relay are connected in series to form a main negative circuit.

[0007] Beneficial Effects:

[0008] 1. Rational space layout: Each component is arranged in an orderly manner from left to right, which not only makes the high-voltage electrical architecture clear, but also optimizes the utilization of internal space, reduces the length and complexity of the wiring harness. For example, it can reduce the size of the copper busbar in the BDU, facilitating the routing of the wiring harness; it is also conducive to heat dissipation, weight reduction, and safety improvement. For example, the positive and negative regions are separated and arranged. From the perspective of electrical safety, whether it is maintenance and debugging or the extrusion and collision of the battery pack, the possibility of short circuit between the positive and negative poles is reduced; at the same time, with the above layout method, the high-voltage and low-voltage wires are routed separately, reducing the risk of high-voltage power interfering with the low-voltage wiring harness.

[0009] 2. Modular design reduces the number of BDU mold developments: By dividing the lower housing into different installation areas, components can be directly installed in different installation areas according to customer needs, and the structure of the BDU housing does not need to be redesigned; it reduces the customized design for different vehicle models, enabling the same set of molds to adapt to multiple configurations of BDU, significantly reducing the number and cost of mold development. In addition, it is conducive to modular production, facilitating standardized design and rapid assembly, while simplifying the maintenance and replacement processes and reducing the maintenance cost.

[0010] 3. Shorten the BDU product development cycle and simplify the design process: Modular design allows for rapid configuration based on existing designs, reducing the design work from scratch, accelerating the product development speed; and different installation areas can be developed in parallel by different teams, improving the development efficiency and shortening the overall development cycle.

[0011] 4. Modular design can also simplify the integration process of the battery pack, shorten the design cycle, improve production efficiency, enhance the reusability of the product design scheme, reduce the DV performance verification carried out due to repeated redevelopment, and reduce waste of resources; and the zoned layout facilitates fault diagnosis and component replacement. The functional modular design of each installation area makes the maintenance work more efficient and reduces the vehicle downtime.

[0012] 5. In this application, the main positive relay is connected in parallel with the fast charge relay. This layout allows for flexible switching as needed during normal driving (through the main positive relay) and fast charge mode (through the fast charge relay), while ensuring that the two do not affect each other, improving the system flexibility and charging efficiency.

[0013] Furthermore, a heating component is also provided in the first installation area, and the heating component is connected in parallel or in series with the main positive relay.

[0014] Beneficial effects:

[0015] 1. The integration of heating components further enhances the modularity and integration of the BDU design, making the heating system an integral part of the battery pack's standard configuration. This facilitates standardized production, simplifies the vehicle assembly process, and reduces production costs. Moreover, integrating the heating components in the first installation area, close to key components such as current sensors and main fuses, simplifies maintenance and troubleshooting. In the event that the heating system requires repair or replacement, staff can quickly locate and address the issue, minimizing vehicle downtime.

[0016] 2. The connection method (parallel or series) between the heating components and the main positive relay provides flexibility. A parallel configuration ensures that the heating system can operate independently even when the battery is not connected to the main circuit, making it suitable for preheating when the vehicle is stationary and not started. In contrast, a series configuration ensures that heating only occurs when the battery system is operational, reducing the risk of misoperation. Additionally, the battery management system (BMS) monitors and controls the heating process to ensure safety. The specific connection method can be selected according to the vehicle model.

[0017] Furthermore, the heating component includes a heating fuse and a heating relay connected in series. One end of the heating relay is set in parallel or series with the main positive relay, and one end of the heating fuse is connected to a heating plug.

[0018] Beneficial effects: The modular design of the heating component (including the heating fuse and the heating relay) improves the system's versatility and interchangeability, facilitating the rapid deployment or replacement of heating modules in different vehicle models or for different requirements. This supports the concept of platform-based design and accelerates the development and production cycle of new vehicle models.

[0019] Furthermore, the lower housing is a double-layer structure. The first installation area includes upper and lower layers. The current sensor and the main fuse are arranged in the upper layer of the first installation area, while the pre-charge relay, the heating relay, and the heating fuse are arranged in the lower layer of the first installation area. The second installation area and the third installation area are located in the upper layer of the lower housing. The lower layer of the second installation area and the third installation area is the fourth installation area, where the pre-charge resistor is arranged. The fourth installation area is also used for installing and fixing the wiring harness.

[0020] Beneficial effects:

[0021] 1. Improved space utilization and maintenance convenience: The double-layer structure design makes full use of the vertical space, enabling the orderly and compact arrangement of components. This not only optimizes space utilization but also simplifies the wiring harness layout, reduces wiring harness crossings, decreases electromagnetic interference, and enhances the system's reliability and maintenance convenience. Additionally, the dedicated fourth installation area for fixing the wiring harness can reduce the movement and wear of the wiring harness, improving the overall neatness.

[0022] 2. Enhance modularity and upgrade potential: The hierarchical design makes the functions of each installation area more distinct, facilitating modular production and maintenance. For example, the heating component is independently set in the lower layer, making it easy to adjust or upgrade the heating system according to actual needs without affecting the main circuit in the upper layer, thus improving the flexibility of the system design and its future upgrade potential.

[0023] 3. Optimize thermal management: In addition to fixing the wiring harness, the fourth installation area can also serve as an additional thermal insulation layer. Especially when the heating component is working, it can reduce the thermal impact on the electronic components above, contributing to overall thermal management and maintaining a suitable working temperature inside the battery pack.

[0024] Furthermore, a bottom guard plate is also provided at the bottom of the lower layer of the first installation area; the bottom of the fourth installation area is open.

[0025] Beneficial effects: The bottom guard plate at the bottom of the first installation area protects the wiring harness and components. The fourth installation area has a large heat dissipation requirement, and setting its bottom open is beneficial to the thermal management of the BDU.

[0026] Furthermore, interfaces for installing copper bars or wires are also provided on the upper shell cover, including a three-in-one interface, a main circuit interface, and a fast charging interface.

[0027] Beneficial effects: The settings of the three-in-one interface, the main circuit interface, and the fast charging interface provide high flexibility and scalability for the battery pack and the high-voltage system; different vehicle models or customer requirements can be quickly adapted to different high-voltage electrical architecture configurations by selectively connecting or replacing the copper bars on the interfaces without significantly modifying the basic design, thus accelerating the product development and market response speed.

[0028] Furthermore, anti-electric shock markings are also provided on the surface of the upper shell cover.

[0029] Furthermore, heat dissipation holes are provided in the top area of the upper shell cover where the main fuse is located.

[0030] Beneficial effects: The main fuse inside the BDU has a large heat dissipation requirement, and setting heat dissipation holes on its top is beneficial to the thermal management of the BDU.

[0031] A battery pack includes a box body, a battery module is arranged inside the box body, and a platformized BDU is also arranged inside the box body, and the BDU is electrically connected to the battery module. Description of the Drawings

[0032] Figure 1 It is an assembly drawing of the BDU mold;

[0033] Figure 2 For Figure 1 A structural schematic diagram in another direction;

[0034] Figure 3Schematic diagram of the lower housing;

[0035] Figure 4 is Figure 1 Schematic diagram after omitting the upper shell cover;

[0036] Figure 5 is Figure 4 Exploded schematic diagram of;

[0037] Figure 6 Schematic diagram of the connection of the BDU high-voltage electrical architecture;

[0038] Figure 7 Partial schematic diagram of the battery pack in the second embodiment. Specific implementation manners

[0039] The following is a further detailed description through specific implementation manners:

[0040] The markings in the attached drawings of the specification include: lower housing 1, first installation area 11, bottom guard plate 111, second installation area 12, third installation area 13, fourth installation area 14, wire harness 141, upper shell cover 2, buckle 20, three-in-one positive interface 211, main circuit positive interface 212, fast charge positive interface 213, fast charge negative interface 221, three-in-one negative interface 222, main circuit negative interface 223, anti-electric shock marking 23, heat dissipation holes 24, main fuse 31, main positive relay 32, main negative relay 33, current sensor 34, shunt 35, fast charge relay 41, pre-charge relay 51, pre-charge resistor 52, heating fuse 61, heating relay 62, heating plug 63, box body 100, battery module 101.

[0041] Embodiment 1

[0042] As Figure 1 shown, a platformized BDU includes a lower housing 1 and an upper shell cover 2 for covering the lower housing 1. An installation chamber for installing components is provided on the lower housing 1; the upper shell cover 2 is snap-connected to the lower housing 1 through a buckle 20, and the snap-connection method is a prior art and no substantial improvement has been made in this embodiment, so it will not be elaborated here. Specifically, interfaces for installing copper bars or wires are also provided on the upper shell cover 2, including three-in-one interfaces, main circuit interfaces, and fast charge interfaces; among them, the three-in-one positive interface 211, main circuit positive interface 212, and fast charge positive interface 213 are located in the middle of the upper shell cover 2; the three-in-one negative interface 222, main circuit negative interface 223, and fast charge negative interface 221 are located on one side of the positive interface of the upper shell cover 2. In this embodiment, an anti-electric shock marking 23 is also provided on the upper surface of the upper shell cover 2.

[0043] As Figure 3-4As shown, a first installation area 11, a second installation area 12, and a third installation area 13 are successively arranged on the lower housing 1. A current sensor 34, a main fuse 31, a pre-charge relay 51, and a pre-charge resistor 52 are arranged in the first installation area 11. A main positive relay 32 and a fast charge relay 41 are successively arranged in the second installation area 12. The fast charge relay 41 is arranged in parallel with the main positive relay 32. A main negative relay 33 and a shunt 35 are successively arranged in the third installation area 13.

[0044] As Figure 6 shown, the current sensor 34, the main fuse 31, and the main positive relay 32 are successively connected in series through a copper bar and a wire to form a main positive circuit. The shunt 35 and the main negative relay 33 are connected in series through a wire to form a main negative circuit. The pre-charge relay 51 and the pre-charge resistor 52 form a pre-charge circuit. After the pre-charge relay 51 and the pre-charge resistor 52 are connected in series, they are connected to both ends of the main positive relay 32. The fast charge relay 41 is arranged in parallel with the main positive relay 32 and is used to independently control the on / off of the fast charge circuit. This embodiment further includes a three-in-one circuit. The three-in-one positive interface 211 is connected in parallel with the main positive relay 32 through a wire, and the three-in-one negative interface 222 is connected in series with the main negative relay 33. The three-in-one interface is used to connect the three-in-one controller (OBC, DC / AC, DC / DC) of the vehicle end to complete the AC charging function of the vehicle, the high-voltage to low-voltage power supply function of the vehicle, and the DC to AC inversion function.

[0045] In this embodiment, a heating component is further arranged in the first installation area 11. The heating component is arranged in parallel or in series with the main positive relay 32. Specifically, as Figure 6 shown, the heating component includes a heating fuse 61 and a heating relay 62 that are successively connected in series. One end of the heating relay 62 is arranged in parallel or in series with the main positive relay 32. In this embodiment, the parallel arrangement is taken as an example for illustration, and it can be flexibly selected according to the vehicle model during actual design. One end of the heating fuse 61 is connected to the positive pole of a heating plug 63, and the negative pole of the heating plug 63 is connected to the main negative circuit through a wire.

[0046] In this embodiment, in order to better improve the space utilization rate and enhance modularity, the lower housing 1 is set as a double-layer structure. Among them, the first installation area 11 includes upper and lower layers. As Figure 5 shown, the current sensor 34 and the main fuse 31 are arranged on the upper layer of the first installation area 11. In order to facilitate heat dissipation of the main fuse 31, heat dissipation holes 24 are arranged in the upper shell cover 2 in the top area of the main fuse 31. The pre-charge relay 51, the heating relay 62, and the heating fuse 61 are arranged on the lower layer of the first installation area 11 ( Figure 5 the current sensor 34, the heating relay 62, and the heating fuse 61 are not fully shown in the figure). In this embodiment, a bottom guard plate 111 is further arranged at the bottom of the lower layer of the first installation area 11. The second installation area 12 and the third installation area 13 are located on the upper layer of the lower housing 1.

[0047] As Figure 2 shown, the lower layer of the second installation area 12 and the third installation area 13 is the fourth installation area 14. The pre-charge resistor 52 is arranged in the fourth installation area 14, and the bottom of the fourth installation area 14 is open, which can provide a heat dissipation space for the pre-charge resistor 52 and is beneficial to the thermal management of the BDU. In addition, the fourth installation area 14 is also used to install and fix the wire harness 141, and all connecting wires pass through the fourth installation area 14, which is beneficial to reducing the crossing of the wire harness 141, reducing electromagnetic interference, improving the reliability of the system and the convenience of maintenance. And by setting the fourth installation area 14, an effective installation point can be provided for the wire harness 141 to reduce the movement and wear of the wire harness 141 and improve the overall neatness.

[0048] A platformized BDU provided by the present application can reduce the number of BDU mold developments, reduce the development cost of the BDU product of the battery pack and shorten the development cycle of the BDU product, improve the versatility of the BDU product, and at the same time enhance the product integration and platformized design concept and improve the product R & D level.

[0049] Embodiment 2

[0050] This embodiment provides a battery pack, as Figure 7 shown, including a box body 100. A battery module 101 and the BDU disclosed in Embodiment 1 are arranged in the box body 100, and the BDU is electrically connected to the battery module 101.

[0051] The above are only the embodiments of the present invention. The present invention is not limited to the fields involved in this embodiment case, and common knowledge such as specific structures and characteristics known in the solutions is not described in detail here. It should be noted that for those skilled in the art, without departing from the structure of the present invention, several deformations and improvements can still be made, and these should also be regarded as the protection scope of the present invention, and these will not affect the implementation effect of the present invention and the practicality of the patent. The protection scope required by this application should be subject to the content of its claims, and the specific implementation manners described in the specification can be used to explain the content of the claims.

Claims

1. A platform BDU, comprising a lower shell and an upper shell cover for covering the lower shell, characterized in that: The lower shell is provided with a first installation area, a second installation area, and a third installation area from left to right. The first installation area is provided with a current sensor, a main fuse, a pre-charge relay, and a pre-charge resistor. The second installation area is provided with a main positive relay and a fast charge relay. The fast charge relay is arranged in parallel with the main positive relay. The pre-charge relay and the pre-charge resistor are connected in series and connected to the two ends of the main positive relay. The third installation area is provided with a main negative relay and a shunt. The current sensor, the main fuse, and the main positive relay are connected in series in sequence through copper busbars and wires to form a main positive circuit, and the shunt and the main negative relay are connected in series to form a main negative circuit.

2. A platform-based BDU according to claim 1, characterized in that: The first installation area is also provided with a heating component, and the heating component is arranged in parallel or in series with the main positive relay.

3. A platform-based BDU according to claim 2, characterized in that: The heating component comprises a heating fuse and a heating relay which are connected in series in sequence, one end of the heating relay is connected in parallel or in series with the main positive relay, and one end of the heating fuse is connected with a heating plug-in.

4. A platform-based BDU according to claim 3, characterized in that: The lower shell body has a double-layer structure, the first installation area includes an upper and lower layer, the current sensor and the main fuse are arranged on the upper layer of the first installation area, and the pre-charge relay, the heating relay, and the heating fuse are arranged on the lower layer of the first installation area; the second installation area and the third installation area are located on the upper layer of the lower shell body, the lower layer of the second installation area and the third installation area is the fourth installation area, the pre-charge resistor is arranged in the fourth installation area, and the fourth installation area is also used to install and fix the wiring harness.

5. A platform-based BDU according to claim 4, characterized in that: A bottom guard plate is also provided at the bottom of the lower layer of the first installation area; and the bottom of the fourth installation area is open.

6. A platform-based BDU according to claim 5, characterized in that: The upper shell cover is also provided with interfaces for installing copper bars or wires, including a three-in-one interface, a main circuit interface, and a fast charging interface.

7. A platform-based BDU according to claim 6, characterized in that: The surface of the upper shell cover is also provided with an anti-electric shock mark.

8. A platform-based BDU according to claim 7, characterized in that: The upper shell cover is located at the top area of ​​the main fuse and is provided with heat dissipation holes.

9. A battery pack, comprising a box, in which a battery module is arranged, characterized in that: A platform-based BDU as described in any one of claims 1 to 8 is also provided in the box, and the BDU is electrically connected to the battery module.

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