Filter integrated with fuse short-circuit protection

Abstract

The utility model discloses a filter integrated with fuse short circuit protection, which comprises an installation main body, and a copper bar module, a fuse module and a filtering module which are arranged on the installation main body, the installation main body comprises a fuse installation area, a magnetic core installation groove and a plurality of filtering capacitor installation grooves, the fuse mounting area comprises a first fixing hole, a second fixing hole and a third fixing hole; the copper bar module comprises a direct current negative electrode copper bar and a direct current positive electrode copper bar. According to the integrated fuse short-circuit protection filter disclosed by the utility model, the filter and the short-circuit protection fuse holder are integrated into one part, so that the number of parts of an electric drive controller is reduced, the installation space is saved, and the purchase and transportation cost of the parts is reduced; and finally, the installation steps can be reduced, and the installation procedures of the assembly can be reduced.

Description

Technical Field

[0001] This utility model belongs to the field of filter technology, specifically relating to a filter with integrated fuse short-circuit protection. Background Technology

[0002] In high-voltage power transmission products such as new energy vehicles, the internal structural layout design of various automobiles increasingly demands integration and miniaturization of electric drive products. This is particularly true for all-in-one electric drive controllers (integrating inverters and on-board charging units), which require the integration of multiple functional outputs and multi-functional power control boxes. Furthermore, the product's external dimensions and volume must be minimized for easier assembly and fewer sub-components. To ensure the safety and EMC reliability of the entire all-in-one system circuitry, the fuse function is integrated into the filter. This primarily protects the charging circuit during charging and discharging, preventing excessive charging and discharging current and ensuring charging and discharging safety as well as the overall vehicle's EMC reliability.

[0003] like Figure 1 As shown, in traditional designs, filters and fuse short-circuit protectors are usually designed as several independent parts; fuse short-circuit protectors typically consist of two parts: a fuse and a fuse holder. The fuse holder connects the fuse and the copper busbar. This part uses the fuse to provide overcurrent protection to the high and low voltage charging integrated module on the electric drive controller for safety during battery pack charging and discharging.

[0004] The filter section will first be connected to the high-voltage harness from the battery pack end, and then transferred to the fuse short-circuit protector. This allows the electric drive controller to effectively shield the mutual interference signals from the battery pack and the high and low voltage charging integrated module. The entire system has both filter shielding function and can protect the controller during high and low voltage charging, thereby meeting the safety design requirements of the control motor.

[0005] The problem with this traditional technology is:

[0006] First, it is necessary to design two independent parts, and to design and manage both parts.

[0007] Secondly, during installation, the independent installation positions of the filter and the fuse short-circuit protector must be considered, making it impossible to reduce the installation space.

[0008] Third, assembling two parts will inevitably increase the number of screws, making the BOM (Bill of Materials) more lengthy.

[0009] Fourth, the increased number of parts will lead to increased procurement and transportation costs, thereby increasing the cost of the electric drive controller assembly.

[0010] Finally, the increase in the number of parts will inevitably lead to a more complicated installation process. Each additional part means an additional step and an additional risk.

[0011] Therefore, further improvements will be made to address the aforementioned issues. Utility Model Content

[0012] The main objective of this invention is to provide a filter with integrated fuse short-circuit protection. By integrating the filter and the fuse holder for short-circuit protection into a single component, the invention reduces the number of parts in the electric drive controller, saves installation space, reduces the cost of purchasing and transporting parts, and also shortens the installation steps and assembly procedures.

[0013] To achieve the above objectives, this utility model provides a filter with integrated fuse short-circuit protection, comprising a mounting body and a copper busbar module, a fuse module, and a filter module mounted on the mounting body, wherein:

[0014] The mounting body includes a fuse mounting area, a magnetic core mounting slot, and several filter capacitor mounting slots. The fuse mounting area includes a first fixing hole, a second fixing hole, and a third fixing hole.

[0015] The copper busbar module includes a DC negative copper busbar and a DC positive copper busbar. The DC negative copper busbar includes an integrally formed first body, a first bent portion, and a second bent portion. The first bent portion and the second bent portion are respectively located at both ends of the first body and both the first bent portion and the second bent portion face a first direction. The DC positive copper busbar includes an integrally formed second body, a third bent portion, and a fourth bent portion. The third bent portion and the fourth bent portion are respectively located at both ends of the second body. The third bent portion faces the first direction, and the fourth bent portion faces a second direction opposite to the first direction. The second body is provided with a first extension portion, and the first extension portion is provided with a fourth fixing hole.

[0016] The fuse module includes a fuse and a positive copper busbar located in the fuse mounting area. The fuse has a fifth fixing hole and a sixth fixing hole at both ends, and the fuse has a seventh fixing hole and an eighth fixing hole at both ends. The fifth fixing hole, the fourth fixing hole, and the first fixing hole are aligned from top to bottom (and fixed with bolts). The sixth fixing hole, the seventh fixing hole, and the second fixing hole are aligned from top to bottom (and fixed with bolts). The eighth fixing hole and the third fixing hole are aligned from top to bottom (and fixed with bolts).

[0017] The filtering module includes a magnetic core and several filtering capacitors. The magnetic core is installed in the magnetic core mounting slot and the filtering capacitors are installed in the filtering capacitor mounting slot.

[0018] As a further preferred embodiment of the above technical solution, the first body and the second body respectively penetrate the magnetic core.

[0019] As a further preferred embodiment of the above technical solution, the first body and the second body are respectively connected to the filter capacitor.

[0020] As a further preferred embodiment of the above technical solution, the copper busbar module further includes a grounding copper busbar, which is connected to the filter capacitor.

[0021] As a further preferred embodiment of the above technical solution, the magnetic core is snap-fitted into the magnetic core mounting slot. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the structure of an existing filter.

[0023] Figure 2 This is a schematic diagram of the structure of this utility model.

[0024] Figure 3 This is a schematic diagram of the installation body of this utility model.

[0025] Figure 4 This is a structural schematic diagram of the present invention (the mounting body is hidden).

[0026] Figure 5 This is a structural schematic diagram of the present invention (the mounting body is hidden).

[0027] The reference numerals in the attached drawings include: 100, mounting body; 110, fuse mounting area; 111, first fixing hole; 112, second fixing hole; 113, third fixing hole; 120, magnetic core mounting slot; 130, filter capacitor mounting slot; 200, copper busbar module; 210, DC negative copper busbar; 211, first body; 212, first bend; 213, second bend; 220, DC positive copper busbar; 221, second body; 222, third bend; 223, fourth bend; 224, first extension; 225, fourth fixing hole; 230, grounding copper busbar; 300, fuse module; 310, fuse; 311, fifth fixing hole; 312, sixth fixing hole; 320, fuse positive copper busbar; 321, seventh fixing hole; 322, eighth fixing hole; 400, filter module; 410, magnetic core; 420, filter capacitor. Detailed Implementation

[0028] The following description is intended to disclose the present invention so that those skilled in the art can implement it. The preferred embodiments described below are merely examples, and other obvious variations will occur to those skilled in the art. The basic principles of the present invention defined in the following description can be applied to other embodiments, modifications, improvements, equivalents, and other technical solutions that do not depart from the spirit and scope of the present invention.

[0029] This utility model discloses a filter with integrated fuse short-circuit protection. The specific embodiments of the utility model are further described below with reference to preferred embodiments.

[0030] In the embodiments of this utility model, those skilled in the art will note that the grounding copper busbar and the like involved in this utility model can be considered as prior art.

[0031] Preferred embodiment.

[0032] like Figure 2-5 As shown, this utility model discloses a filter with integrated fuse short-circuit protection, including a mounting body 100 and a copper busbar module 200, a fuse module 300, and a filter module 400 mounted on the mounting body 100, wherein:

[0033] The mounting body 100 includes a fuse mounting area 110, a magnetic core mounting groove 120 and a plurality of filter capacitor mounting grooves 130. The fuse mounting area 110 includes a first fixing hole 111, a second fixing hole 112 and a third fixing hole 113.

[0034] The copper busbar module 200 includes a DC negative copper busbar 210 and a DC positive copper busbar 220. The DC negative copper busbar 210 includes an integrally formed first body 211, a first bending portion 212, and a second bending portion 213. The first bending portion 212 and the second bending portion 213 are respectively located at both ends of the first body 211, and both the first bending portion 212 and the second bending portion 213 face a first direction. The DC positive copper busbar 220 includes an integrally formed second body 221, a third bending portion 222, and a fourth bending portion 223. The third bending portion 222 and the fourth bending portion 223 are respectively located at both ends of the second body 221. The third bending portion 222 faces a first direction, and the fourth bending portion 223 faces a second direction opposite to the first direction. The second body 221 is provided with a first extension portion 224, and the first extension portion 224 is provided with a fourth fixing hole 225.

[0035] The fuse module 300 includes a fuse 310 and a fuse positive copper busbar 320 located in the fuse mounting area 110. The fuse 310 has a fifth fixing hole 311 and a sixth fixing hole 312 at both ends. The fuse positive copper busbar 320 has a seventh fixing hole 321 and an eighth fixing hole 322 at both ends. The fifth fixing hole 311, the fourth fixing hole 225 and the first fixing hole 111 are aligned from top to bottom (and fixed with bolts). The sixth fixing hole 312, the seventh fixing hole 321 and the second fixing hole 112 are aligned from top to bottom (and fixed with bolts). The eighth fixing hole 322 and the third fixing hole 113 are aligned from top to bottom (and fixed with bolts).

[0036] The filtering module 400 includes a magnetic core 410 and a plurality of filtering capacitors 420. The magnetic core 410 is mounted in the magnetic core mounting slot 120 and the filtering capacitors 420 are mounted in the filtering capacitor mounting slot 130.

[0037] Specifically, the first body 211 and the second body 221 respectively penetrate the magnetic core 410.

[0038] More specifically, the first body 211 and the second body 221 are respectively connected to the filter capacitor 420.

[0039] Furthermore, the copper busbar module 200 also includes a grounding copper busbar 230, which is connected to the filter capacitor 420.

[0040] Furthermore, the magnetic core 410 is snap-fitted into the magnetic core mounting slot 120.

[0041] Regarding this utility model:

[0042] The concept of this utility model is to integrate the outer shell of the filter component and the fuse holder of the short-circuit protector into a single part through injection molding. This new part needs to include all the interfaces of the fuse holder copper busbar, as well as all the interfaces originally belonging to the filter copper busbar, thus reserving the mounting positions for connecting the high and low voltage charging integrated module and the fuse, thereby retaining the function of the fuse holder. Simultaneously, during the injection molding process, bolt holes for mounting and fixing the fuse and copper busbar interfaces for mounting the high and low voltage charging integrated module need to be pre-drilled. The new structure needs to simultaneously include the two main functional interfaces: the filter negative copper busbar and the high and low voltage charging integrated module negative copper busbar, allowing the use of a single negative copper busbar interface when connecting the high and low voltage charging integrated module.

[0043] By using a one-piece injection molding process, the mounting body not only encloses the positive and negative terminals of the DC copper busbar but also the positive copper busbar that acts on the fuse holder, thus integrating the short-circuit protection function of the fuse. The DC positive copper busbar, through its own structure, integrates the function of the negative copper busbar of the fuse holder.

[0044] By integrating the components, approximately 20% to 30% of the original filter and fuse holder costs can be saved. This includes costs for developing parts, transportation, installation, and management, as well as reducing the risks associated with multiple installation steps. In addition, the integrated components can save approximately 30% of the space compared to the original design, allowing more internal space in the electric drive controller for other components, or directly reducing the total space of the electric drive controller.

[0045] It is worth mentioning that the technical features such as the grounding copper busbar involved in this utility model patent application should be regarded as prior art. The specific structure, working principle and possible control methods and spatial arrangement of these technical features can be adopted by conventional choices in the field, and should not be regarded as the inventive point of this utility model patent. This utility model patent will not be further elaborated in detail.

[0046] For those skilled in the art, modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A filter with integrated fuse short-circuit protection, characterized in that, It includes a mounting body and a copper busbar module, a fuse module, and a filter module mounted on the mounting body, wherein: The mounting body includes a fuse mounting area, a magnetic core mounting slot, and several filter capacitor mounting slots. The fuse mounting area includes a first fixing hole, a second fixing hole, and a third fixing hole. The copper busbar module includes a DC negative copper busbar and a DC positive copper busbar. The DC negative copper busbar includes an integrally formed first body, a first bent portion, and a second bent portion. The first bent portion and the second bent portion are respectively located at both ends of the first body and both the first bent portion and the second bent portion face a first direction. The DC positive copper busbar includes an integrally formed second body, a third bent portion, and a fourth bent portion. The third bent portion and the fourth bent portion are respectively located at both ends of the second body. The third bent portion faces the first direction, and the fourth bent portion faces a second direction opposite to the first direction. The second body is provided with a first extension portion, and the first extension portion is provided with a fourth fixing hole. The fuse module includes a fuse and a positive copper busbar located in the fuse mounting area. The fuse has a fifth fixing hole and a sixth fixing hole at both ends, and the fuse has a seventh fixing hole and an eighth fixing hole at both ends. The fifth fixing hole, the fourth fixing hole, and the first fixing hole are aligned from top to bottom. The sixth fixing hole, the seventh fixing hole, and the second fixing hole are aligned from top to bottom. The eighth fixing hole and the third fixing hole are aligned from top to bottom. The filtering module includes a magnetic core and several filtering capacitors. The magnetic core is installed in the magnetic core mounting slot and the filtering capacitors are installed in the filtering capacitor mounting slot.

2. The filter with integrated fuse short-circuit protection according to claim 1, characterized in that, The first body and the second body respectively penetrate the magnetic core.

3. The filter with integrated fuse short-circuit protection according to claim 2, characterized in that, The first body and the second body are respectively connected to the filter capacitor.

4. The filter with integrated fuse short-circuit protection according to claim 1, characterized in that, The copper busbar module also includes a grounding copper busbar, which is connected to the filter capacitor.

5. The filter with integrated fuse short-circuit protection according to claim 1, characterized in that, The magnetic core is snapped into the magnetic core mounting slot.

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