Integrated BDU metal plate support structure

Abstract

The utility model relates to the technical field of BDU supports, in particular to an integrated BDU sheet metal support structure, which comprises a sheet metal support, the sheet metal support comprises a mounting plate, and two side ends of the mounting plate are bent upwards by 90 degrees to form side walls and then bent towards the side direction of the mounting plate by 90 degrees to form a connecting plate; the top of the mounting plate is used for fixing an electric device, and the electric device is located between the two side walls; a bolt mounting hole is formed in the connecting plate, and a bolt penetrates into the bolt mounting hole, so that the metal plate bracket is fixed in the accommodating cavity of the battery pack through the bolt; the surface of the metal plate support is provided with an insulating pressure-resistant coating. According to the integrated BDU metal plate support structure, the metal plate support is arranged to be of a metal plate bending structure, mold opening is not needed, the machining period is short, meanwhile, compared with a conventional injection molding part, a metal plate part has higher strength and smaller weight, and the lightweight design requirement of a battery pack is met.

Description

Technical Field

[0001] The utility model relates to the technical field of BDU brackets, in particular to an integrated BDU sheet metal bracket structure. Background Art

[0002] The high-voltage distribution box battery pack disconnect unit (BDU) is used to connect the power battery pack system of new energy vehicles with the vehicle control box or controller. It is usually composed of electrical components such as main positive / main negative relays, pre-charge / heating relays, fuses, pre-charge resistors, shunts or Hall sensors. The BDU bracket structure is generally used to fix these electrical components and connect the copper busbars in series to the wiring harness.

[0003] The invention application with publication (announcement) number CN115642372A discloses a highly integrated BDU, which is applied to a battery. The BDU has a lower box body and a BDU cover arranged on the top of the lower box body. The BDU includes: a BDU bottom shell, which is arranged on the inner bottom of the lower box body; a number of electrical components are installed on the BDU bottom shell, and the electrical components include a main relay, a heating relay, a pre-charging resistor, a main fuse and a pre-charging relay, etc.

[0004] As described in the technical solution above, the BDU bottom shell is a conventional bracket structure, mainly used to support and fix electrical components such as the main relay, heating relay, pre-charge resistor, main fuse, and pre-charge relay. In conventional BDU bracket structures, the BDU bracket is usually an insulating injection-molded plastic part, which requires mold opening and has a long processing cycle. In addition, to ensure the structural strength of the bracket, the bracket after injection molding needs to have a large wall thickness, resulting in a large deadweight of the bracket, which does not meet the lightweight design requirements of the battery pack. To solve the above technical problems, it is necessary to provide an integrated BDU sheet metal bracket structure. Utility Model Content

[0005] In view of this, the utility model proposes an integrated BDU sheet metal bracket structure, which, by setting the sheet metal bracket as a sheet metal bending structure, does not require mold opening and has a short processing cycle. At the same time, the sheet metal parts have higher strength and smaller weight than conventional injection molded parts, which meets the lightweight design requirements of the battery pack.

[0006] The technical solution of the present utility model is achieved as follows:

[0007] The utility model provides an integrated BDU sheet metal bracket structure, comprising a sheet metal bracket, wherein the sheet metal bracket comprises a mounting plate, the two side ends of the mounting plate are bent upward 90 degrees to form side walls, and the upper ends of the side walls are bent 90 degrees to the sides of the mounting plate to form a connecting plate;

[0008] The top of the mounting plate is used to fix electrical components, and the electrical components are located between the two side walls;

[0009] The connecting plate is provided with a bolt mounting hole, wherein the bolt is inserted into the bolt mounting hole to fix the sheet metal bracket in the accommodating cavity of the battery pack by the bolt;

[0010] The surface of the sheet metal bracket is provided with an insulating pressure-resistant coating.

[0011] On the basis of the above technical solution, preferably, the bolt mounting hole is a waist-shaped hole, and a plurality of the bolt mounting holes are provided on the connecting plate.

[0012] On the basis of the above technical solution, preferably, the other two side ends of the mounting plate are bent downward by 90 degrees to form a reinforcing rib structure.

[0013] On the basis of the above technical solution, preferably, the sheet metal bracket further includes a pre-filled relay mounting stud, a heating relay mounting stud and a heating fuse mounting column, wherein,

[0014] Two of the pre-charge relay mounting studs are fixed at the middle position of the top of the mounting plate;

[0015] Two heating relay mounting studs and two heating fuse mounting studs are fixed on the top of the mounting plate respectively;

[0016] The heating relay mounting stud is located at the rear side of the pre-charge relay mounting stud;

[0017] The heating fuse mounting column is located at the rear side of the heating relay mounting stud.

[0018] On the basis of the above technical solution, preferably, the sheet metal bracket further includes a main negative relay mounting stud and a current sensor mounting column, wherein,

[0019] Two main negative relay mounting studs and two current sensor mounting studs are fixed on the top of the mounting plate respectively;

[0020] The main negative relay mounting stud is located to the right of the pre-charge relay mounting stud;

[0021] The current sensor mounting post is located on the right side of the main negative relay mounting stud.

[0022] On the basis of the above technical solution, preferably, the sheet metal bracket further includes a main positive relay mounting stud, a pre-charge resistor mounting stud and a main fuse mounting stud, wherein,

[0023] Two of the main positive relay mounting studs, two of the pre-charging resistor mounting studs, and two of the main fuse mounting studs are fixed on the top of the mounting plate;

[0024] The main positive relay mounting stud is located on the left side of the pre-charge relay mounting stud;

[0025] The pre-charging resistor mounting stud is located on the left side of the main positive relay mounting stud;

[0026] The main fuse mounting stud is located at the rear side of the pre-charging resistor mounting stud.

[0027] On the basis of the above technical solution, preferably, the main fuse mounting stud, the heating fuse mounting column, and the current sensor mounting column are all screwed with insulating columns.

[0028] On the basis of the above technical solution, preferably, the top of the sheet metal bracket is provided with a main positive relay positioning protrusion and a main negative relay positioning protrusion, wherein,

[0029] The main positive relay positioning protrusion is located between the pre-charging resistor mounting stud and the main positive relay mounting stud;

[0030] The main negative relay positioning protrusion is located between the current sensor mounting column and the main negative relay mounting stud.

[0031] On the basis of the above technical solution, preferably, positive and negative markings are provided on the top of the sheet metal bracket and at the position corresponding to the pre-charge relay mounting stud, as well as at the position corresponding to the heating relay mounting stud.

[0032] On the basis of the above technical solution, preferably, a plurality of wiring harness installation holes are vertically provided on the top of the sheet metal bracket.

[0033] The integrated BDU sheet metal bracket structure of the utility model has the following advantages over the prior art:

[0034] (1) By setting the sheet metal bracket as a sheet metal bending structure, no mold opening is required and the processing cycle is short. At the same time, the sheet metal parts have higher strength and simpler structure than conventional injection molded parts. At the same time, compared with other sheet metal structures, they have smaller weight, which meets the lightweight design requirements of the battery pack.

[0035] (2) By providing an insulating and pressure-resistant coating on the surface of the sheet metal bracket, the insulation between the sheet metal bracket and the electrical components is facilitated, while the pressure resistance level of the sheet metal bracket is improved. At the same time, by providing the other two side ends of the mounting plate to be bent downward 90 degrees to form a reinforcing rib structure, the structural strength of the sheet metal bracket is further improved.

[0036] (3) By providing the main positive relay positioning protrusion and the main negative relay positioning protrusion, it is easy to realize the positioning installation of the positive relay and the main negative relay to prevent reverse installation.

[0037] (4) By setting positive and negative marks on the top of the sheet metal bracket and at the position corresponding to the pre-charge relay installation stud, and at the position corresponding to the heating relay installation stud, it is convenient to position and install the pre-charge relay and the heating relay, and prevent them from being installed upside down. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0039] Figure 1 This is a three-dimensional diagram of an integrated BDU sheet metal bracket structure of the utility model;

[0040] Figure 2 This is a partial three-dimensional diagram of an integrated BDU sheet metal bracket structure of the utility model;

[0041] Figure 3 This is a schematic diagram of the use status of an integrated BDU sheet metal bracket structure of the utility model;

[0042] In the figure: 1. Sheet metal bracket; 2. Electrical components; 11. Mounting plate; 12. Pre-charge relay mounting stud; 13. Heating relay mounting stud; 14. Heating fuse mounting post; 15. Main negative relay mounting stud; 16. Current sensor mounting post; 17. Main positive relay mounting stud; 18. Pre-charge resistor mounting stud; 19. Main fuse mounting stud; 101. Bolt mounting hole; 102. Main positive relay positioning protrusion; 103. Main negative relay positioning protrusion; 104. Positive and negative identification; 105. Wiring harness mounting hole; 111. Side wall; 112. Connecting plate. DETAILED DESCRIPTION

[0043] The following will be combined with the specific embodiments of the present invention to clearly and completely describe the technical solutions of the present invention. Obviously, the embodiments described are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0044] like Figure 1-3As shown, the utility model provides an integrated BDU sheet metal bracket structure, including a sheet metal bracket 1. The sheet metal bracket 1 is a sheet metal bending structure, which is made of SPCC steel with a wall thickness of 1.0 mm. After bending, the surface is electrophoretically treated to form an insulating and voltage-resistant coating. The thickness of the insulating and voltage-resistant coating is ≥20 μm. The electrophoretic material is epoxy resin, silicone rubber, or polytetrafluoroethylene. The insulating and voltage-resistant coating is used to improve the structural strength and insulation performance of the sheet metal bracket 1.

[0045] In the prior art, the wall thickness of conventional injection-molded BDU brackets is not less than 1.2 mm. However, in an integrated BDU sheet metal bracket structure of the present invention, the wall thickness of the sheet metal bracket 1 is 1.0 mm and is a sheet metal part. Therefore, the overall weight is lighter and the structural strength is higher, which meets the lightweight design requirements of the battery pack. At the same time, the sheet metal bracket 1 is obtained by sheet metal, and no mold opening is required, and the processing cycle is shorter.

[0046] like Figure 1 As shown, the sheet metal bracket 1 includes a mounting plate 11, the two side ends of the mounting plate 11 are first bent upward 90 degrees to form a side wall 111, and then the upper end of the side wall 111 is bent 90 degrees to the side of the mounting plate 11 to form a connecting plate 112, and the other two side ends of the mounting plate 11 are bent downward 90 degrees to form a reinforcing rib structure. Through this structure, the sheet metal bracket 1 forms a channel steel structure, and the inner side of the groove is used to install the electrical device 2 to protect the electrical device 2. Specifically, as shown in FIG. Figure 2 As shown, the electrical component 2 is fixed on the top of the mounting plate 11 and is located between the two side walls 111 .

[0047] like Figure 2 As shown, a bolt mounting hole 101 is provided on the connecting plate 112. The function of the bolt mounting hole 101 is to insert a bolt so as to fix the sheet metal bracket 1 in the accommodating cavity of the battery pack by means of the bolt. The battery pack is not drawn in the legend. Furthermore, in order to facilitate the installation of the bolt, the bolt mounting hole 101 is a waist-shaped hole, and in order to improve the fixing effect of the sheet metal bracket 1, a plurality of bolt mounting holes 101 are provided on the connecting plate 112.

[0048] In the integrated BDU sheet metal bracket structure, the sheet metal bracket 1 also includes a pre-charge relay mounting stud 12, a heating relay mounting stud 13, a heating fuse mounting column 14, a main negative relay mounting stud 15, a current sensor mounting column 16, a main positive relay mounting stud 17, a pre-charge resistor mounting stud 18, and a main fuse mounting stud 19.

[0049] Among them, two pre-filling relay mounting studs 12 are fixed at the middle position of the top of the mounting plate 11; two heating relay mounting studs 13 and two heating fuse mounting columns 14 are fixed on the top of the mounting plate 11 respectively; the heating relay mounting studs 13 are located on the rear side of the pre-filling relay mounting studs 12; the heating fuse mounting columns 14 are located on the rear side of the heating relay mounting studs 13.

[0050] Two main negative relay mounting studs 15 and two current sensor mounting columns 16 are fixed on the top of the mounting plate 11 respectively; the main negative relay mounting stud 15 is located on the right side of the pre-charge relay mounting stud 12; the current sensor mounting column 16 is located on the right side of the main negative relay mounting stud 15.

[0051] Two main positive relay mounting studs 17, pre-charging resistor mounting studs 18, and main fuse mounting studs 19 are fixed on the top of the mounting plate 11 respectively; the main positive relay mounting stud 17 is on the left side of the pre-charging relay mounting stud 12; the pre-charging resistor mounting stud 18 is on the left side of the main positive relay mounting stud 17; the main fuse mounting stud 19 is on the rear side of the pre-charging resistor mounting stud 18.

[0052] In the above structure, the main fuse mounting stud 19, the heating fuse mounting column 14 and the current sensor mounting column 16 are all screwed with insulating columns, and the top of the insulating column is provided with a connecting end, which is a threaded column structure.

[0053] like Figure 2 As shown, the electrical device 2 includes a pre-charge relay, a heating relay, a heating fuse, a main negative relay, a current sensor, a main positive relay, a pre-charge resistor, and a main fuse. The pre-charge relay, the heating relay, the main negative relay, the main positive relay, and the pre-charge resistor are respectively installed on the corresponding mounting studs, and the main fuse, the heating fuse, and the current sensor are respectively installed on the corresponding insulating columns. The installation method adopts a matching structure of nuts and studs, that is, nuts are screwed on the mounting studs, and the installation and fixation of each electrical device 2 are achieved by tightening the nuts.

[0054] In the integrated BDU sheet metal support structure, in order to prevent the positive relay and the main negative relay from being installed in reverse, a main positive relay positioning protrusion 102 and a main negative relay positioning protrusion 103 are provided on the top of the sheet metal support 1. Figure 1 As shown, the main positive relay positioning protrusion 102 is located between the pre-charging resistor mounting stud 18 and the main positive relay mounting stud 17; the main negative relay positioning protrusion 103 is located between the current sensor mounting column 16 and the main negative relay mounting stud 15; Figure 2As shown, the wire harness connection terminals of the positive relay and the main negative relay are both on the side. Therefore, when the positive relay and the main negative relay are installed in reverse, their wire harness connection terminals will interfere with the corresponding positioning protrusions. Therefore, the positive relay and the main negative relay can be positioned and installed through the main positive relay positioning protrusion 102 and the main negative relay positioning protrusion 103 to prevent reverse installation.

[0055] At the same time, in order to prevent the pre-charge relay and the heating relay from being installed in reverse, at the top of the sheet metal bracket 1 and at the positions corresponding to the pre-charge relay mounting stud 12 and the positions corresponding to the heating relay mounting stud 13, positive and negative markings 104 are provided to distinguish the installation angles of the pre-charge relay and the heating relay to prevent reverse installation.

[0056] In addition, as Figure 3 shown, several wire harness installation holes 105 are vertically and throughly provided at the top of the sheet metal bracket 1. The function of the wire harness installation holes 105 is for wire harness fixation. There are also tie holes provided on the connecting plate 112 for bundling low-voltage wire harnesses. Figure 2 Among them, five wire harness installation holes 105 are provided. One is provided at the front side of the pre-charge relay, one is provided at the rear side of the main negative relay and on the right side of the heating fuse, and the other three are provided on the right side of the current sensor and arranged in a triangular shape.

[0057] In addition, as Figure 3 shown, several "U"-shaped wire harness brackets are also welded and fixed at the top of the sheet metal bracket 1, and their functions are the same as those of the wire harness installation holes 105. Figure 2 Among them, three wire harness brackets are provided. One is provided between the main positive relay and the pre-charge resistor, another is provided between the heating relay and the pre-charge resistor, and the last one is provided between the main negative relay and the current sensor.

[0058] The usage method of an integrated BDU sheet metal bracket structure of the present utility model is as follows:

[0059] As Figure 2 shown, install the pre-charge relay, the heating relay, the main negative relay, the main positive relay, and the pre-charge resistor on the corresponding studs respectively, and install the main fuse, the heating fuse, and the current sensor on the corresponding insulating columns respectively. The installation and fixation method adopts the cooperation structure of a nut and a stud, that is: after the above electrical components 2 are installed on the corresponding studs, screw nuts on the corresponding studs, and then tighten the nuts to realize the installation and fixation of each electrical component 2.

[0060] The above are only the preferred embodiments of the present utility model and are not intended to limit the present utility model. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present utility model shall be included within the protection scope of the present utility model.

Claims

1. An integrated BDU sheet metal support structure, comprising a sheet metal support (1), characterized in that: The sheet metal bracket (1) comprises a mounting plate (11), the two side ends of the mounting plate (11) are bent upward at 90 degrees to form a side wall (111), and the upper end of the side wall (111) is bent 90 degrees to the side of the mounting plate (11) to form a connecting plate (112); The top of the mounting plate (11) is used to fix the electrical device (2), and the electrical device (2) is located between the two side walls (111); The connecting plate (112) is provided with a bolt mounting hole (101), and the bolt mounting hole (101) is used to penetrate a bolt so as to fix the sheet metal bracket (1) in the accommodating cavity of the battery pack by means of the bolt; The surface of the sheet metal bracket (1) is provided with an insulating pressure-resistant coating.

2. The integrated BDU sheet metal support structure according to claim 1, characterized in that: The bolt mounting hole (101) is a waist-shaped hole, and a plurality of the bolt mounting holes (101) are provided on the connecting plate (112).

3. The integrated BDU sheet metal support structure according to claim 1, characterized in that: The other two side ends of the mounting plate (11) are bent downward by 90 degrees to form a reinforcing rib structure.

4. The integrated BDU sheet metal support structure according to claim 1, characterized in that: The sheet metal bracket (1) further includes a pre-filled relay mounting stud (12), a heating relay mounting stud (13) and a heating fuse mounting post (14), wherein: Two pre-charge relay mounting studs (12) are fixed at the middle position of the top of the mounting plate (11); Two heating relay mounting studs (13) and two heating fuse mounting studs (14) are fixedly arranged on the top of the mounting plate (11); The heating relay mounting stud (13) is located at the rear side of the pre-charge relay mounting stud (12); The heating fuse mounting column (14) is located at the rear side of the heating relay mounting stud (13).

5. The integrated BDU sheet metal support structure according to claim 4, characterized in that: The sheet metal bracket (1) further includes a main negative relay mounting stud (15) and a current sensor mounting post (16), wherein: Two main negative relay mounting studs (15) and two current sensor mounting studs (16) are fixedly arranged on the top of the mounting plate (11); The main negative relay mounting stud (15) is located on the right side of the pre-charge relay mounting stud (12); The current sensor mounting post (16) is located on the right side of the main negative relay mounting stud (15).

6. The integrated BDU sheet metal support structure according to claim 5, characterized in that: The sheet metal bracket (1) further comprises a main positive relay mounting stud (17), a pre-charging resistor mounting stud (18) and a main fuse mounting stud (19), wherein: Two of the main positive relay mounting studs (17), the pre-charging resistor mounting studs (18), and the main fuse mounting studs (19) are fixedly arranged on the top of the mounting plate (11); The main positive relay mounting stud (17) is located on the left side of the pre-charge relay mounting stud (12); The pre-charging resistor mounting stud (18) is located on the left side of the main positive relay mounting stud (17); The main fuse mounting stud (19) is located at the rear side of the pre-charging resistor mounting stud (18).

7. The integrated BDU sheet metal support structure according to claim 6, characterized in that: Insulation columns are screwed onto the main fuse mounting stud (19), the heating fuse mounting column (14), and the current sensor mounting column (16).

8. The integrated BDU sheet metal support structure according to claim 6, characterized in that: The top of the sheet metal bracket (1) is provided with a main positive relay positioning protrusion (102) and a main negative relay positioning protrusion (103), wherein: The main positive relay positioning protrusion (102) is located between the pre-charging resistor mounting stud (18) and the main positive relay mounting stud (17); The main negative relay positioning protrusion (103) is located between the current sensor mounting post (16) and the main negative relay mounting stud (15).

9. The integrated BDU sheet metal support structure according to claim 6, characterized in that: Positive and negative markings (104) are provided on the top of the sheet metal bracket (1) and at positions corresponding to the pre-charge relay mounting studs (12), as well as at positions corresponding to the heating relay mounting studs (13).

10. The integrated BDU sheet metal support structure according to claim 6, characterized in that: A plurality of wiring harness mounting holes (105) are vertically provided on the top of the sheet metal bracket (1).

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