Full-automatic assembly high-voltage distribution box integrated with BMS (Battery Management System)

Abstract

The utility model relates to a full-automatic assembly high-voltage distribution box integrated with a BMS, which comprises a main positive circuit, a quick charge positive electrode circuit, a main negative circuit, a quick charge negative electrode circuit, a booster circuit and a BMS module, the main positive circuit, the quick charge positive electrode circuit and the booster circuit are connected in parallel, and the main negative circuit is connected in parallel with the quick charge negative electrode circuit; a capacitor circuit is connected in series between the fast charge positive electrode circuit and the negative electrode main circuit, and a boost capacitor C1 and a capacitor relay which are connected in series are arranged on the capacitor circuit; the BMS module collects electrical parameters of the main positive circuit, the quick charge positive circuit, the main negative circuit, the quick charge negative circuit or the booster circuit through the collection circuit; and the BMS module controls execution electric devices in the main positive circuit, the quick charge positive circuit, the main negative circuit, the quick charge negative circuit or the booster circuit through the high-voltage control circuit. According to the full-automatic assembly high-voltage distribution box integrated with the BMS, the positive and negative main circuits, the quick charging circuit, the booster circuit and the BMS module are all integrated into the BDU to form a high-integration structure.

Description

Technical Field

[0001] The utility model relates to the technical field of new energy vehicles, and in particular to a fully automated assembly high-voltage distribution box integrated with a BMS. Background Art

[0002] The BDU high-voltage distribution unit is responsible for the distribution and management of high-voltage system power supply, and provides functions such as charging and discharging control, overload and short-circuit protection, and high-voltage sampling for new energy vehicles.

[0003] Traditional BDU internal electrical components are fixed with bolts, and are also connected to the copper busbars with bolts for locking and conduction. This bolt assembly process requires manual installation, which is time-consuming, inefficient, has many specifications, and is prone to bolt back-twisting problems. It cannot meet the needs of automated assembly. In addition, the overlap between the copper busbar and the electrical components will have contact internal resistance, resulting in heat rise and reduced efficiency. In severe cases, it will cause failures due to excessive local temperature.

[0004] The low-voltage control circuit, pre-charging circuit, boost circuit, high-voltage collection circuit, etc. of the traditional BDU internal circuit all use the traditional wiring harness connection method. This method requires manual layout of the wiring harness and cannot achieve fully automated production. In addition, the wiring harness connection method is messy and unsightly, inefficient, and the wiring terminals are easy to loosen, the wires are poorly connected, and the wire ends fall off, causing circuit failures and even vehicle fires.

[0005] Due to the above-mentioned assembly method, the prior art adopts a separate arrangement of BDU (high-voltage distribution box) and BMS (battery management system). This arrangement has a low degree of integration and cannot meet the requirements of automated production and assembly. It also occupies a large space in the battery pack, has low installation efficiency, and high parts costs. Utility Model Content

[0006] The embodiment of the utility model provides a fully automated assembly high-voltage distribution box integrated with a BMS, so as to solve the problem in the prior art that the assembly process cannot be automated due to the unreasonable structure of the BDU.

[0007] In order to achieve the above purpose, the embodiment of the utility model provides the following technical solutions:

[0008] An integrated BMS fully automated assembly high-voltage distribution box, including a main positive circuit, a fast charging positive circuit, a main negative circuit, a fast charging negative circuit, a boosting circuit and a BMS module. The main positive circuit, the fast charging positive circuit and the boosting circuit are all connected in parallel, and the main negative circuit is connected in parallel with the fast charging negative circuit; A capacitor circuit is serially provided between the fast charging positive circuit and the negative main circuit, and a boosting capacitor C1 and a capacitor relay connected in series with each other are provided on the capacitor circuit; The BMS module respectively collects the electrical parameters of the main positive circuit, the fast charging positive circuit, the main negative circuit, the fast charging negative circuit or the boosting circuit through a collection circuit; The BMS module respectively controls the actuating electrical components in the main positive circuit, the fast charging positive circuit, the main negative circuit, the fast charging negative circuit or the boosting circuit through a high-voltage control circuit.

[0009] Further, the boosting circuit is provided with a charging boosting relay, and the charging boosting relay is connected in parallel with a grounded capacitor C2.

[0010] Further, the main positive circuit is connected in parallel with a pre-charging circuit, and the pre-charging circuit is provided with a pre-charging relay and a pre-charging resistor R connected in series.

[0011] Further, a main positive relay and an intelligent fuse are serially provided on the main positive circuit.

[0012] Further, all the electrical components of the main positive circuit, the fast charging positive circuit, the main negative circuit, the fast charging negative circuit, the boosting circuit and the BMS module are installed in the housing, and each electrical component and the BMS module are on the same layer. Several copper bars for constructing the main positive circuit, the fast charging positive circuit, the main negative circuit, the fast charging negative circuit and the boosting circuit are provided on one side of the housing, and a flexible circuit board integrating the control circuit and the collection circuit of the BMS module is provided on the other side of the housing.

[0013] Further, a receiving cavity is provided in the housing for each electrical component, and the receiving cavity is surrounded by first partitions on four sides.

[0014] Further, a second partition for isolating copper bars is provided at the installation position of the BMS module in the housing, and a reinforcing rib layer is provided on the second partition.

[0015] Further, the BMS module is located on one side of all the electrical components of the main positive circuit, the fast charging positive circuit, the main negative circuit, the fast charging negative circuit and the boosting circuit.

[0016] Further, all the electrical components of the main positive circuit, the fast charging positive circuit and the boosting circuit are located on one side of the housing, and the main negative circuit, the fast charging negative circuit, the boosting capacitor C1 and the capacitor relay are located on the other side of the housing.

[0017] Further, a fast - charge positive - electrode relay is provided in the fast - charge positive - electrode circuit, a main - negative relay is provided in the main - negative circuit, and a fast - charge negative - electrode relay is provided in the fast - charge negative - electrode circuit; in the housing, a main - positive relay, a fast - charge positive - electrode relay, and a boost relay are arranged in sequence from left to right; in the housing, a main - negative relay, a fast - charge negative - electrode relay, a capacitor relay, and a boost capacitor C1 are arranged in sequence from left to right.

[0018] The embodiments of the present utility model have the following advantages:

[0019] A fully - automated assembly high - voltage distribution box integrating BMS provided by the present utility model integrates the positive and negative main circuits, the fast - charging circuit, the boost circuit, the high - voltage acquisition circuit, and the low - voltage control circuit of the BMS module into the BDU, forming a highly integrated structure.

[0020] A fully - automated assembly high - voltage distribution box integrating BMS provided by the present utility model uses laser welding for electrical components and copper bars to replace the wire - harness connection scheme, and also replaces the wire - harness scheme through FPC integration, solving the problems of messy and complex wire harnesses, poor connection, and wire - head detachment. At the same time, it solves the problem that the traditional BDU and BMS are separately arranged, occupying a large space in the battery system. Bolt - locking conduction between electrical components and copper bars has a low degree of automation, requires manual assembly, takes a long time and has low efficiency, and is prone to bolt loosening. It can also prevent local overheating caused by the contact internal resistance between copper bars and electrical components, reducing the risk of reduced efficiency or even fire and explosion, making the internal layout of this integrated design more beautiful and tidy, and the connection more safe and reliable. Further, it increases the available space of the battery system and improves the installation efficiency of the product. Description of the Drawings

[0021] In order to more clearly illustrate the embodiments of the present utility model or the technical solutions in the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the drawings in the following description are only exemplary, and for those of ordinary skill in the art, without creative efforts, other implementation drawings can be obtained according to the provided drawings.

[0022] The structures, ratios, sizes, etc. shown in this specification are only used to cooperate with the content disclosed in the specification for those familiar with this technology to understand and read, and are not used to limit the limiting conditions for the implementation of the present utility model. Therefore, they do not have technical essence. Any modification of the structure, change of the proportional relationship, or adjustment of the size, without affecting the effects that the present utility model can produce and the purposes that can be achieved, should still fall within the scope covered by the technical content disclosed in the present utility model.

[0023] Figure 1 It is a circuit diagram of a fully - automated assembly high - voltage distribution box integrating BMS provided by an embodiment of the present utility model;

[0024] Figure 2 An exploded view of a fully automated assembled high-voltage distribution box integrating BMS provided for an embodiment of the utility model.

[0025] In the figure:

[0026] 1. Main positive circuit; 2. Fast charging positive circuit; 3. Main negative circuit; 4. Fast charging negative circuit; 5. Boosting circuit; 6. BMS module; 7. Capacitor circuit; 8. Boosting capacitor C1; 9. Capacitor relay; 10. Main positive relay; 11. Intelligent fuse; 12. Charging boosting relay; 13. Capacitor C2; 14. Housing; 15. Flexible circuit board; 16. First partition; 17. Second partition; 18. Reinforcing rib layer; 19. Fast charging positive relay; 20. Fast charging negative relay; 21. Pre-charging circuit; 22. Main negative relay. Specific embodiments

[0027] The following specific embodiments illustrate the implementation manners of the present utility model. Those skilled in the art can easily understand other advantages and effects of the present utility model from the content disclosed in this specification. Obviously, the described embodiments are part of the embodiments of the present utility model, rather than all of them. Based on the embodiments in the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present utility model.

[0028] As Figure 1 shown, a fully automated assembled high-voltage distribution box integrating BMS includes a main positive circuit 1, a fast charging positive circuit 2, a main negative circuit 3, a fast charging negative circuit 4, a boosting circuit 5 and a BMS module 6. The main positive circuit 1, the fast charging positive circuit 2 and the boosting circuit 5 are all connected in parallel. The main negative circuit 3 is connected in parallel with the fast charging negative circuit 4. A capacitor circuit 7 is connected in series between the fast charging positive circuit 2 and the negative main circuit. The capacitor circuit 7 is provided with a boosting capacitor C1 8 and a capacitor relay 9 connected in series with each other. The present technology provides a BDU with an 800V high-voltage fast charging function. The BMS controls the on-off of the boosting circuit 5 and the capacitor relay 9. By charging the boosting capacitor C1 8, the boosting function of the fast charging circuit is realized, such as boosting the fast charging circuit from 400V to 800V. In order to meet the pre-charging function of the BDU, the main positive circuit 1 is connected in parallel with a pre-charging circuit 21. The pre-charging circuit 21 is provided with a pre-charging relay and a pre-charging resistor R connected in series.

[0029] A main positive relay 10 and an intelligent fuse 11 are connected in series on the main positive circuit 1. In order to simplify the circuit and expand the function of the intelligent fuse 11 to the maximum, the intelligent fuse 11 is arranged on the parallel bus of the main positive circuit 1, the fast charging positive circuit 2 and the boosting circuit 5, so that the intelligent fuse 11 can control the on-off of multiple circuits.

[0030] The BMS module 6 collects the electrical parameters of the main positive circuit 1, fast charge positive circuit 2, main negative circuit 3, fast charge negative circuit 4 or boost circuit 5 through a collection circuit. The electrical parameters include circuit current, circuit voltage, etc. In this technology, multiple circuits are arranged in parallel. Therefore, a collection point is set after the multiple circuits are connected in parallel, and then a collection point is set in each circuit, which can reduce the number of collections and greatly simplify the circuit structure.

[0031] The BMS module 6 controls the actuating electrical components in the main positive circuit 1, fast charge positive circuit 2, main negative circuit 3, fast charge negative circuit 4 or boost circuit 5 through a high-voltage control circuit. The actuating electrical components include relays, fuses, sensors, etc.

[0032] The boost circuit 5 is provided with a charging boost relay 12, and a capacitor C2 13 grounded is connected in parallel with the charging boost relay 12. The capacitor C2 13 plays a role in filtering and voltage stabilization.

[0033] An important innovation of this technology is to eliminate wire harness assembly and bolt assembly, forming a highly integrated product, which can meet the requirements of fully automated assembly. Specifically, laser welding is used instead of bolt fastening to integrate the BMS into the BDU. It has comprehensive functions and is basically applicable to all types of high-voltage distribution boxes. Specifically, all the electrical components of the main positive circuit 1, fast charge positive circuit 2, main negative circuit 3, fast charge negative circuit 4, boost circuit 5 and the BMS module 6 are installed in the housing 14, and each electrical component and the BMS module 6 are on the same layer. One side of the housing 14 is provided with several copper bars for constructing the main positive circuit 1, fast charge positive circuit 2, main negative circuit 3, fast charge negative circuit 4 and boost circuit 5, and the other side of the housing 14 is provided with a flexible circuit board 15 integrating the control circuit and collection circuit of the BMS module 6.

[0034] A receiving cavity is provided in the housing 14 for each electrical component. The receiving cavity is surrounded by the first partition plates 16 on four sides. The first partition plates 16 are used to isolate the electrical components to prevent heat exchange between the electrical components. Moreover, several raised strip structures are provided on the first partition plates 16 to provide a certain gap between the partition plates and the electrical components for the heat dissipation of the electrical components.

[0035] A second partition plate 17 for isolating copper bars is provided at the installation position of the BMS module 6 in the housing 14. The second partition plate 17 is provided with a reinforcing rib layer 18 for isolating the BMS module 6 from the copper bars at its bottom.

[0036] The BMS module 6 is located on one side of all the electrical components of the main positive circuit 1, fast charge positive circuit 2, main negative circuit 3, fast charge negative circuit 4, and boost circuit 5, facilitating the layout of the copper bars. All the copper bars are arranged on one layer, and the electrical components with connection relationships are arranged together.

[0037] All the electrical components of the main positive circuit 1, fast charge positive circuit 2, and boost circuit 5 are located on one side of the housing 14, and all the electrical components of the main negative circuit 3, fast charge negative circuit 4, boost capacitor C1 8, and capacitor relay 9 are located on the other side of the housing 14. The various components on the positive and negative circuits are separated and the associated electrical components are arranged together, facilitating the layout of the copper bars and enabling all the copper bars to be arranged on one layer. Specifically, the fast charge positive circuit 2 is provided with a fast charge positive relay 19, the main negative circuit 3 is provided with a main negative relay 22, and the fast charge negative circuit 4 is provided with a fast charge negative relay 20; the main positive relay 10, fast charge positive relay 19, and boost relay are successively arranged in the housing 14 from left to right; the main negative relay 22, fast charge negative relay 20, capacitor relay 9, and boost capacitor C1 8 are successively arranged in the housing 14 from left to right. This structural layout of the BDU enables all the copper bars to be arranged on one layer, greatly simplifies the product structure, forms a highly integrated structure, and moreover, arranging the copper bars on one layer facilitates the heat dissipation of the copper bars. A water channel is arranged at the bottom of the housing 14 to form an efficient heat dissipation structure.

[0038] Although the present invention has been described in detail above with general descriptions and specific embodiments, based on the present invention, some modifications or improvements can be made, which are obvious to those skilled in the art. Therefore, these modifications or improvements made without departing from the spirit of the present invention all fall within the scope of protection required by the present invention.

Claims

1. An integrated BMS fully automated assembly high-voltage distribution box, characterized in that: It includes a main positive circuit, a fast charge positive circuit, a main negative circuit, a fast charge negative circuit, a boost circuit and a BMS module. The main positive circuit, the fast charge positive circuit and the boost circuit are all connected in parallel, and the main negative circuit is connected in parallel with the fast charge negative circuit; A capacitor circuit is serially arranged between the fast charge positive circuit and the negative main circuit, and a boost capacitor C1 and a capacitor relay connected in series with each other are arranged on the capacitor circuit; The BMS module respectively collects the electrical parameters of the main positive circuit, the fast charge positive circuit, the main negative circuit, the fast charge negative circuit or the boost circuit through a collection circuit; The BMS module respectively controls the actuating electrical components in the main positive circuit, the fast charge positive circuit, the main negative circuit, the fast charge negative circuit or the boost circuit through a high-voltage control circuit.

2. The fully automated assembled high-voltage distribution box integrating BMS according to claim 1, characterized in that: The boost circuit is provided with a charging boost relay, and the charging boost relay is shunted with a grounded capacitor C2.

3. An integrated BMS fully automated assembly high-voltage distribution box according to claim 1, characterized in that: The main positive circuit is shunted with a precharge circuit, and the precharge circuit is provided with a precharge relay and a precharge resistor R connected in series.

4. An integrated BMS fully automated assembly high-voltage distribution box according to claim 1, characterized in that: A main positive relay and an intelligent fuse are connected in series on the main positive circuit.

5. An integrated BMS fully automated assembly high-voltage distribution box according to any one of claims 1-4, characterized in that: All the electrical components of the main positive circuit, the fast charge positive circuit, the main negative circuit, the fast charge negative circuit, the boost circuit and the BMS module are installed in a housing, and each electrical component and the BMS module are on the same layer. Several copper bars for constructing the main positive circuit, the fast charge positive circuit, the main negative circuit, the fast charge negative circuit and the boost circuit are arranged on one side of the housing, and a flexible circuit board integrating the control circuit and the collection circuit of the BMS module is arranged on the other side of the housing.

6. The fully automated assembled high-voltage distribution box integrated with BMS according to claim 5, characterized in that: A receiving cavity is arranged in the housing for each electrical component, and the receiving cavity is surrounded by first partition boards on four sides.

7. An integrated BMS fully automated assembly high-voltage distribution box according to claim 5, characterized in that: A second partition board for isolating copper bars is arranged at the installation position of the BMS module in the housing, and a reinforcing rib layer is arranged on the second partition board.

8. An integrated BMS fully automated assembly high-voltage distribution box according to claim 5, characterized in that: The BMS module is located on one side of all the electrical components of the main positive circuit, the fast charge positive circuit, the main negative circuit, the fast charge negative circuit and the boost circuit.

9. An integrated BMS fully automated assembly high-voltage distribution box according to claim 5, characterized in that: All the electrical components of the main positive circuit, the fast charge positive circuit and the boost circuit are located on one side of the housing, and the main negative circuit, the fast charge negative circuit, the boost capacitor C1 and the capacitor relay are located on the other side of the housing.

10. An integrated BMS fully automated assembly high-voltage distribution box according to claim 9, characterized in that: The fast charge positive circuit is provided with a fast charge positive relay, the main negative circuit is provided with a main negative relay, and the fast charge negative circuit is provided with a fast charge negative relay; The main positive relay, the fast charge positive relay and the boost relay are arranged in sequence from left to right in the housing; The main negative relay, the fast charge negative relay, the capacitor relay and the boost capacitor C1 are arranged in sequence from left to right in the housing.

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