High-voltage all-in-one controller power distribution interface installation device

Abstract

The utility model relates to the field of new energy heavy trucks and engineering machinery, and particularly discloses a high-voltage all-in-one controller power distribution interface mounting device. The high-voltage all-in-one controller comprises a range extending power distribution interface, a first upper assembly electric interface, an electric heating power distribution interface, an electric air conditioner power distribution interface, an oil pump DCAC driving module interface, an air pump DCAC driving module interface, an electric defrosting power distribution interface and a second upper assembly electric interface, and the power distribution interfaces are distributed on the side face of the high-voltage all-in-one controller in an upper layer and a lower layer in a centralized mode. And the wire outlet faces the horizontal direction. The quick-plug connector is reasonable in structure and convenient to install, and the horizontal outlets and the layered interfaces are designed, so that the identifiability can be effectively improved, the assembly and maintenance efficiency can be improved, and the damage risk of the quick-plug connector can be reduced.

Description

Technical Field

[0001] The present application relates to the field of new energy heavy trucks and engineering machinery, and more specifically, to a high-voltage all-in-one controller power distribution interface installation device. Background Art

[0002] In new energy vehicle technology, the high-voltage all-in-one controller plays a vital role, which integrates key functions such as motor controller, oil pump DCAC drive module, air pump DCAC drive module, DC / DC converter and power distribution module. This integrated solution reduces the use of separate components, improves the utilization efficiency of vehicle space, and helps reduce manufacturing costs.

[0003] However, as the functions integrated in the controller increase day by day, especially the power distribution function, a higher demand is placed on the number of high-voltage power interfaces.

[0004] Existing designs usually connect to external devices through quick-connect connectors, which are usually concentrated on the side of the controller. Since the connector outlet direction is downward, the position of the connector on the side of the box is designed to be an eaves-like structure. The connector is fixed upside down on the eaves, and the vehicle wiring harness connected to it is routed downward, so that the vehicle wiring harness will not interfere with the side of the controller. This layout limits the increase in the number of interfaces without changing the overall width of the controller. For vehicles with high-power upper drives or hybrid range extensions, the existing design does not have a corresponding high-power distribution interface, resulting in the inability to meet the vehicle's demand for the number of power distribution interfaces. At the same time, the downward arrangement of the high-voltage interface brings certain challenges during the assembly and maintenance of the vehicle. When technicians are performing connection operations, it is difficult to directly observe the anti-misinsertion mark on the interface, which not only increases the operational risk and may cause damage to the high-voltage components, but also affects the efficiency of assembly and maintenance.

[0005] Therefore, there is an urgent need for a high-voltage all-in-one controller power distribution interface installation device to meet this challenge. Utility Model Content

[0006] In order to solve the above technical problems, this application is proposed. This application provides a high-voltage all-in-one controller power distribution interface installation device, which cancels the eaves-type installation position structure of the quick-plug connector, avoids the additional structural design protruding from the box; adjusts the outlet direction of the quick-plug connector from the original downward to the horizontal direction; implements a layered arrangement design for the power distribution interface; and adds an extended-range power distribution interface and an additional upper assembly power distribution interface.

[0007] Specifically, the present application provides the following technical solution: a high-voltage multi-in-one controller power distribution interface installation device, which includes: an extended-range power distribution interface, a first upper assembly power distribution interface, an electric heating power distribution interface, an electric air-conditioning power distribution interface, an oil pump DCAC drive module interface, an air pump DCAC drive module interface, an electric defrosting power distribution interface, and a second upper assembly power distribution interface. These power distribution interfaces are centrally arranged in two layers on the side of the high-voltage multi-in-one controller, and the outlet is oriented horizontally.

[0008] Preferably, the upper layer of the high-voltage multi-in-one controller is arranged in sequence from left to right with the extended-range power distribution interface, the first upper assembly power distribution interface, the electric heating power distribution interface, the electric air-conditioning power distribution interface, and the oil pump DCAC drive module interface. The lower layer of the high-voltage multi-in-one controller is arranged in sequence from left to right with the second upper assembly power distribution interface, the electric defrosting power distribution interface, and the air pump DCAC drive module interface; wherein, the electric heating power distribution interface and the second upper assembly power distribution interface are arranged in vertical alignment, the electric air-conditioning power distribution interface and the electric defrosting power distribution interface are arranged in vertical alignment, and the oil pump DCAC drive module interface and the air pump DCAC drive module interface are arranged in vertical alignment.

[0009] Preferably, the extended-range power distribution interface is connected to a first fuse through a first copper bar. The other end of the first fuse is connected to the terminal of a first contactor through a second copper bar. The other terminal of the first contactor is connected to the busbar copper bar through a third copper bar, forming a complete power distribution loop.

[0010] Preferably, the first upper assembly power distribution interface is connected to a second fuse through a fourth copper bar. The other end of the second fuse is connected to the terminal of a second contactor through a fifth copper bar. The other terminal of the second contactor is connected to the busbar copper bar through a third copper bar, forming a complete power distribution loop.

[0011] Preferably, the third copper bar serves as a common conductive connection, which simultaneously connects the busbar copper bar, the first contactor, and the second contactor, allowing current to flow through the third copper bar to the first contactor and the second contactor simultaneously.

[0012] Preferably, the high-voltage multi-in-one controller further includes: a PCB board of the power distribution unit. The PCB board of the power distribution unit is configured with a control circuit for providing power to the low-voltage 24V coils of the first contactor and the second contactor.

[0013] Preferably, the electric heating power distribution interface, the electric air conditioning power distribution interface, the oil pump DCAC drive module interface, the air pump DCAC drive module interface, the electric defrost power distribution interface and the second upper assembly power distribution interface all connect the various power modules inside the high-voltage all-in-one controller to the tail of the quick-plug connector through copper wires.

[0014] Preferably, the assembly width dimension of the high-voltage all-in-one controller is 482 mm.

[0015] Preferably, the high-voltage all-in-one controller further comprises: four base feet, which together provide stable support for the high-voltage all-in-one controller.

[0016] Compared with the prior art, the present application provides a high-voltage all-in-one controller power distribution interface installation device. This design cancels the eaves-type installation position structure of the quick-plug connector, changes the quick-plug connector outlet installation direction from downward to horizontal, and the power distribution interface adopts an upper and lower layered layout. This design method not only enables assembly and maintenance personnel to more intuitively identify the interface characteristics of each connector, improves the efficiency of assembly and maintenance, but also effectively reduces the possibility of damage to the connector during plug-in and unplug operations, and reduces operational risks. At the same time, under the premise that the width of the controller remains unchanged, the design adds an extended-range power distribution interface and an additional upper assembly power distribution interface, which helps to improve the adaptability of the controller and meet the needs of different vehicle models and different power configurations. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] By describing the embodiments of the present application in more detail in conjunction with the accompanying drawings, the above and other purposes, features and advantages of the present application will become more apparent. The accompanying drawings are used to provide a further understanding of the embodiments of the present application and constitute a part of the specification. Together with the embodiments of the present application, they are used to explain the present application and do not constitute a limitation of the present application. In the accompanying drawings, the same reference numerals generally represent the same components or steps.

[0018] Figure 1 The figure illustrates an axial schematic diagram of a high-voltage all-in-one controller power distribution interface installation device according to an embodiment of the present application.

[0019] Figure 2 The diagram shows a partial top view of a high-voltage all-in-one controller power distribution interface installation device according to an embodiment of the present application.

[0020] Figure 3 The diagram illustrates a schematic diagram of the internal range extension and upper installation circuit of a high-voltage all-in-one controller power distribution interface installation device according to an embodiment of the present application.

[0021] In the figure: 1 extended-range power distribution interface, 2 first upper assembly power distribution interface, 3 electric heating power distribution interface, 4 electric air conditioner power distribution interface, 5 oil pump DCAC drive module interface, 6 air pump DCAC drive module interface, 7 electric defrosting power distribution interface, 8 second upper assembly power distribution interface, 9 third copper bar, 10 busbar copper bar, 11 PCB of the power distribution unit, 12 feet, 1-1 first copper bar, 1-2 first fuse, 1-3 second copper bar, 1-4 first contactor, 2-1 fourth copper bar, 2-2 second fuse, 2-3 fifth copper bar, 2-4 second contactor. Detailed implementation manners

[0022] Next, exemplary embodiments according to the present application will be described in detail with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments of the present application. It should be understood that the present application is not limited by the exemplary embodiments described herein.

[0023] Embodiment:

[0024] The high-voltage power distribution interfaces of the multi-in-one controller in the embodiments of the present application are connected to the outside using quick-connect connectors and are centrally arranged on the side of the controller. Specifically, as Figure 1 shown, the high-voltage multi-in-one controller power distribution interface installation device in the embodiments of the present application includes: an extended-range power distribution interface 1, a first upper assembly power distribution interface 2, an electric heating power distribution interface 3, an electric air conditioner power distribution interface 4, an oil pump DCAC drive module interface 5, an air pump DCAC drive module interface 6, an electric defrosting power distribution interface 7, and a second upper assembly power distribution interface 8.

[0025] In the existing design, the high-voltage interfaces are arranged downward, which can effectively prevent rainwater from entering the controller through the connector interfaces and causing electrical failures. In actual vehicle applications, the controller is usually arranged under the cab or in the engine compartment and is not easily exposed to rain; instead, the outgoing line direction downward is more likely to come into contact with the water splash and dust near the ground, and connectors with high protection performance are required. The horizontal outgoing line is not easily exposed to the water splash and dust near the ground, which can reduce the risk of the controller failing due to water ingress.

[0026] In addition, in the existing design, the high-voltage interfaces are arranged in a row. If there is a subsequent power distribution requirement and it is changed from one row to two rows, the length of the controller will increase, resulting in insufficient space in the vehicle to arrange the controller. If two rows are arranged, not only the length dimension of the controller is not increased, but also if there are other power distribution requirements later, it can be directly increased to three rows as long as sufficient electrical clearance is ensured. In this way, the length dimension of the controller will not increase due to the increase in the number of interfaces.

[0027] Therefore, in the embodiment of the present application, these power distribution interfaces are divided into two layers, upper and lower, and are centrally arranged on the side of the high-voltage all-in-one controller, with the outlet facing the horizontal direction. Specifically, the upper layer of the high-voltage all-in-one controller is arranged from left to right with the extended-range power distribution interface 1, the first upper assembly power distribution interface 2, the electric heating power distribution interface 3, the electric air conditioning power distribution interface 4 and the oil pump DCAC drive module interface 5, and the lower layer of the high-voltage all-in-one controller is arranged from left to right with the second upper assembly power distribution interface 8, the electric defrost power distribution interface 7 and the air pump DCAC drive module interface 6. The electric heating power distribution interface 3 is aligned with the second upper assembly power distribution interface 8 in the upper and lower directions, the electric air conditioning power distribution interface 4 is aligned with the electric defrost power distribution interface 7 in the upper and lower directions, and the oil pump DCAC drive module interface 5 is aligned with the air pump DCAC drive module interface 6 in the upper and lower directions.

[0028] Since this design changes the outlet direction of the connector from downward to horizontal, the side of the controller box no longer needs to be designed as an eaves structure, and the connector can be directly fixed on the flat side of the box. This design makes the plugging and unplugging of the connector more intuitive and convenient, especially suitable for application scenarios with limited space or frequent plugging and unplugging. At the same time, this layered arrangement of the power distribution interface can improve space utilization and make the identification and management of each interface clearer and more orderly.

[0029] like Figure 2 As shown, the electric heating power distribution interface 3, the electric air conditioning power distribution interface 4, the oil pump DCAC drive module interface 5, the air pump DCAC drive module interface 6, the electric defrosting power distribution interface 7 and the second upper assembly power distribution interface 8 are connected to each power module inside the high-voltage all-in-one controller with the tail of the quick-plug connector through copper wires. And the assembly width of the high-voltage all-in-one controller is about 482mm.

[0030] like Figure 1 and Figure 2 As shown, the high-voltage all-in-one controller also includes four base feet 12, which together provide stable support for the high-voltage all-in-one controller.

[0031] With the development of new energy, some special vehicles are also gradually developing towards electrification, especially for vehicles with high-power upper drive or hybrid range extension, which require high-power power distribution, and the existing design does not have a corresponding interface to match it, resulting in the inability to meet the vehicle's demand for the number of power distribution interfaces. Therefore, this application provides a greater output power through the newly added extended-range power distribution interface 1 and the first upper assembly power distribution interface 2. However, the above-mentioned method of connecting with copper wires cannot meet the needs of large current transmission, and it is difficult to apply to the extended-range power distribution interface 1 and the first upper assembly power distribution interface 2. Compared with copper wire connection, copper busbar has a larger surface area, can provide lower resistance and higher current carrying capacity, and is also conducive to heat dissipation. In addition, copper busbar connection can simplify the manufacturing process, improve assembly efficiency, and help to achieve miniaturization and lightweight of equipment. Therefore, in an embodiment of the present application, the wiring scheme of copper busbar connection is used to connect the extended-range power distribution interface 1 and the first upper assembly power distribution interface 2 to each power module inside the high-voltage all-in-one controller.

[0032] Specifically, Figure 3 As shown, the extended-range power distribution interface 1 is connected to the first fuse 1-2 through the first copper bar 1-1, the other end of the first fuse 1-2 is connected to the terminal of the first contactor 1-4 through the second copper bar 1-3, and the other end terminal of the first contactor 1-4 is connected to the busbar copper bar 10 through the third copper bar 9 to form a complete power distribution circuit; the first upper assembly power distribution interface 2 is connected to the second fuse 2-2 through the fourth copper bar 2-1, the other end of the second fuse 2-2 is connected to the terminal of the second contactor 2-4 through the fifth copper bar 2-3, and the other end terminal of the second contactor 2-4 is connected to the busbar copper bar 10 through the third copper bar 9 to form a complete power distribution circuit.

[0033] The third copper bar 9 is used as a common conductive connection, which simultaneously connects the busbar copper bar 10, the first contactor 1-4 and the second contactor 2-4, allowing current to flow to the first contactor 1-4 and the second contactor 2-4 simultaneously through the third copper bar 9. Such a connection method can save internal space and cost.

[0034] In addition, Figure 3 As shown, the high-voltage all-in-one controller also includes a PCB board 11 of a power distribution unit, and the PCB board 11 of the power distribution unit is configured with a control circuit for providing power to the low-voltage 24V coils of the first contactor 1-4 and the second contactor 2-4. The PCB board 11 of the power distribution unit controls the power supply of the low-voltage 24V coils of contactors 1-4 and 2-4 to realize the on-off of contactors 1-4 and 2-4, thereby realizing the on-off of the extended-range power distribution circuit and the first upper assembly power distribution circuit, and meeting the power demand of the whole vehicle.

[0035] In summary, the high-voltage multi-in-one controller power distribution interface installation device according to the embodiments of the present application is illustrated, which includes: an extended-range power distribution interface, a first upper assembly power distribution interface, an electric heating power distribution interface, an electric air-conditioning power distribution interface, an oil pump DCAC drive module interface, an air pump DCAC drive module interface, an electric defrosting power distribution interface, and a second upper assembly power distribution interface. These power distribution interfaces are centrally arranged in two layers on the side of the high-voltage multi-in-one controller, and the outlet is oriented horizontally. The structure of the present utility model is reasonable and convenient for installation. Its horizontal outlet and layered interface design can effectively improve the recognition, increase the assembly and maintenance efficiency, and reduce the risk of damage to the quick-connect connector.

[0036] For those skilled in the art, it is obvious that the present utility model is not limited to the details of the above exemplary embodiments, and without departing from the spirit or basic characteristics of the present utility model, the present utility model can be implemented in other specific forms.

[0037] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present utility model and not to limit them. Although the present utility model has been described in detail with reference to the preferred embodiments, those of ordinary skill in the art should understand that the technical solutions of the present utility model can be modified or equivalently replaced without departing from the spirit of the technical solutions of the present utility model.

Claims

1. A high-voltage all-in-one controller power distribution interface installation device, characterized in that: The invention comprises: an extended-range power distribution interface (1), a first upper body power distribution interface (2), an electric heating power distribution interface (3), an electric air conditioning power distribution interface (4), an oil pump DCAC drive module interface (5), an air pump DCAC drive module interface (6), an electric defrosting power distribution interface (7) and a second upper body power distribution interface (8), wherein the power distribution interfaces are arranged in two layers, upper and lower, on the side of the high-voltage all-in-one controller, with the outlet facing the horizontal direction.

2. The high-voltage all-in-one controller power distribution interface installation device according to claim 1, characterized in that: The upper layer of the high-voltage all-in-one controller is arranged from left to right in sequence with the extended-range power distribution interface (1), the first upper assembly power distribution interface (2), the electric heating power distribution interface (3), the electric air conditioning power distribution interface (4) and the oil pump DCAC drive module interface (5), and the lower layer of the high-voltage all-in-one controller is arranged from left to right in sequence with the second upper assembly power distribution interface (8), the electric defrost power distribution interface (7) and the air pump DCAC drive module interface (6); The electric heating power distribution interface (3) and the second upper assembly power distribution interface (8) are aligned vertically, the electric air conditioning power distribution interface (4) and the electric defrosting power distribution interface (7) are aligned vertically, and the oil pump DCAC drive module interface (5) and the air pump DCAC drive module interface (6) are aligned vertically.

3. The high-voltage all-in-one controller power distribution interface installation device according to claim 2, characterized in that: The extended-range power distribution interface (1) is connected to the first fuse (1-2) via a first copper bar (1-1), the other end of the first fuse (1-2) is connected to the terminal of the first contactor (1-4) via a second copper bar (1-3), and the other end of the terminal of the first contactor (1-4) is connected to the busbar copper bar (10) via a third copper bar (9), thereby forming a complete power distribution circuit.

4. The high-voltage all-in-one controller power distribution interface installation device according to claim 3, characterized in that: The first upper assembly power supply interface (2) is connected to the second fuse (2-2) via a fourth copper bar (2-1), the other end of the second fuse (2-2) is connected to the terminal of the second contactor (2-4) via a fifth copper bar (2-3), and the other end of the terminal of the second contactor (2-4) is connected to the busbar copper bar (10) via a third copper bar (9), thereby forming a complete power distribution circuit.

5. The high-voltage all-in-one controller power distribution interface installation device according to claim 4, characterized in that: The third copper bar (9) serves as a common conductive connection, which simultaneously connects the busbar copper bar (10), the first contactor (1-4) and the second contactor (2-4), allowing current to flow through the third copper bar (9) to the first contactor (1-4) and the second contactor (2-4) at the same time.

6. The high-voltage all-in-one controller power distribution interface installation device according to claim 5, characterized in that: Also includes: A PCB board (11) of a power distribution unit, wherein the PCB board (11) of the power distribution unit is configured with a control circuit for providing power to the low-voltage 24V coils of the first contactor (1-4) and the second contactor (2-4).

7. The high-voltage all-in-one controller power distribution interface installation device according to claim 1, characterized in that: The electric heating power distribution interface (3), the electric air conditioning power distribution interface (4), the oil pump DCAC drive module interface (5), the air pump DCAC drive module interface (6), the electric defrosting power distribution interface (7) and the second upper assembly power distribution interface (8) all connect the various power modules inside the high-voltage all-in-one controller to the tail of the quick-connect connector through copper wires.

8. The high-voltage all-in-one controller power distribution interface installation device according to claim 1, characterized in that: The assembly width dimension of the high-voltage all-in-one controller is 482 mm.

9. The high-voltage all-in-one controller power distribution interface installation device according to claim 1, characterized in that: Also includes: Four base feet (12), which together provide stable support for the high-voltage all-in-one controller.

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