All-in-one power distribution unit

Abstract

The utility model discloses an all-in-one power distribution unit, which relates to the field of power distribution units and comprises a high-voltage power distribution system and an auxiliary power supply system. The high-voltage power distribution system shunts electric energy output by the high-voltage storage battery and configures the electric energy to the driving unit and the integrated power generation module; the auxiliary power supply system comprises an oil pump DC / AC module, an air pump DC / AC module, a low-voltage DC / DC module, a PTC heating module and a compressor control module, and electric energy of a high-voltage storage battery is distributed to an oil pump motor, an air pump motor, a low-voltage storage battery, low-voltage electric equipment for power supply, a PTC and a compressor through the modules. The all-in-one power distribution unit is used for electric energy distribution, and the working efficiency and reliability of an electrical system are improved.

Description

Technical Field

[0001] This application relates to the field of power distribution units, and in particular to an all-in-one power distribution unit. Background Technology

[0002] High-voltage power distribution systems and auxiliary power supply systems are crucial components of modern power transmission and distribution systems, widely used in industries, data centers, transportation infrastructure, and other scenarios requiring efficient and reliable power supply. Their primary function is to efficiently distribute and manage high-voltage electrical energy, ensuring the safe, stable, and efficient operation of the power supply system. With the continuous growth of modern electricity demand, especially the reliance on stable power supply for high-performance computers (such as data center servers), new energy industries (such as charging piles and high-voltage energy storage equipment), and intelligent manufacturing (such as industrial robots and high-power equipment), the technological level of high-voltage PDUs (Power Distribution Units) has become a key factor determining the efficiency and reliability of the power supply system. Simultaneously, PDUs are gradually evolving from traditional power management tools into intelligent systems integrating multiple functions, enabling: real-time monitoring of electrical data; providing multiple electrical safety guarantees such as overload protection, short-circuit protection, and over-temperature protection; achieving remote control and intelligent scheduling to improve management efficiency; and reducing energy consumption to optimize power usage efficiency.

[0003] The existing high-voltage power distribution and auxiliary power supply systems have technical problems in the following aspects:

[0004] 1. Insufficient system efficiency: Under high load and complex power supply environments, the efficiency of traditional PDU equipment decreases, resulting in problems such as high power loss and insufficient power supply stability.

[0005] 2. Limited Level of Intelligence: Although intelligent PDU devices are becoming increasingly common, their communication protocols often lack unified standards, leading to significant compatibility issues. Furthermore, the response speed and accuracy of their intelligent monitoring systems to abnormal power supply conditions still need improvement.

[0006] 3. Insufficient reliability: Existing PDU equipment is prone to protection mechanism failure when faced with sudden high loads, short circuits, or overvoltages, which may lead to equipment damage or even safety accidents.

[0007] 4. Insufficient flexibility and scalability: Existing PDU devices are often designed for specific application scenarios and are difficult to expand flexibly to meet diverse power supply needs. For scenarios that require frequent adjustments to device layout (such as modular data centers), they lack rapid deployment and reconfiguration capabilities.

[0008] 5. Insufficient environmental adaptability: Many high-voltage PDU devices are poorly adapted to extreme environments (such as high temperature, high humidity, and strong electromagnetic interference), making it difficult to operate stably in complex environments for a long time. Utility Model Content

[0009] The purpose of this application is to provide an all-in-one power distribution unit to improve the efficiency and reliability of electrical systems.

[0010] To achieve the above objectives, this application provides the following solution:

[0011] In a first aspect, this application provides an all-in-one power distribution unit, including: a high-voltage power distribution system and an auxiliary power supply system;

[0012] The high-voltage power distribution system is used to divert the electrical energy output from the high-voltage battery and allocate the electrical energy to the drive unit and the integrated power generation module.

[0013] The high-voltage power distribution system includes a first pre-charging circuit, a power output fuse, a second pre-charging circuit, and a main positive fuse; one end of the first pre-charging circuit is connected to the first end of the high-voltage battery; the other end of the first pre-charging circuit is connected to one end of the power output fuse; the other end of the power output fuse is connected to a drive unit; one end of the second pre-charging circuit is connected to the first end of the high-voltage battery; the other end of the second pre-charging circuit is connected to one end of the main positive fuse; the other end of the main positive fuse is connected to an integrated power generation module.

[0014] The auxiliary power supply system includes an oil pump DC / AC module, an air pump DC / AC module, a low-voltage DC / DC module, a PTC heating module, and a compressor control module;

[0015] The oil pump DC / AC module is used to convert the DC power from the high-voltage bus of the high-voltage battery into AC power and input it to the oil pump motor.

[0016] The air pump DC / AC module is used to convert the DC power from the high-voltage bus of the high-voltage battery into AC power and input it to the air pump motor.

[0017] The low-voltage DC / DC module is used to convert the high-voltage bus DC power of the high-voltage battery into low-voltage power to supply power to the low-voltage battery and low-voltage electrical equipment.

[0018] The PTC heating module is used to transmit the electrical energy output by the high-voltage battery to the PTC heater;

[0019] The compressor control module is used to transmit the electrical energy output by the high-voltage battery to the compressor.

[0020] Optionally, the first pre-charging circuit includes: a first pre-charging resistor, an electrically driven pre-charging contactor, and an electrically driven contactor;

[0021] One end of the electric drive precharge contactor and the other end of the electric drive contactor are both connected to the first end of the high-voltage battery; the other end of the electric drive precharge contactor is connected to one end of the first precharge resistor; the other end of the first precharge resistor and the other end of the electric drive contactor are both connected to one end of the power output fuse.

[0022] Optionally, the second pre-charge circuit includes: a pre-charge contactor, a main positive contactor, and a second pre-charge resistor;

[0023] One end of the precharge contactor and one end of the main positive contactor are both connected to the first end of the high-voltage battery; the other end of the precharge contactor is connected to one end of the second precharge resistor; the other end of the second precharge resistor and the other end of the main positive contactor are both connected to one end of the main positive fuse.

[0024] Optionally, the oil pump DC / AC module includes: a first filter capacitor, a second filter capacitor, a first switching transistor, a second switching transistor, a third switching transistor, a fourth switching transistor, a fifth switching transistor, and a sixth switching transistor;

[0025] One end of the first filter capacitor is connected to the positive terminal of the high-voltage battery; one end of the second filter capacitor is connected to the negative terminal of the high-voltage battery; the other ends of the first filter capacitor and the other ends of the second filter capacitor are connected; the collectors of the first, third, and fifth switching transistors are all connected to the positive terminal of the high-voltage battery; the emitters of the second, fourth, and sixth switching transistors are all connected to the negative terminal of the high-voltage battery; the emitter of the first switching transistor and the collector of the second switching transistor are both connected to the first terminal of the oil pump motor; the emitter of the third switching transistor and the collector of the fourth switching transistor are both connected to the second terminal of the oil pump motor; the emitter of the fifth switching transistor and the collector of the sixth switching transistor are both connected to the third terminal of the oil pump motor.

[0026] Optionally, the air pump DC / AC module includes: a third filter capacitor, a fourth filter capacitor, a seventh switch, an eighth switch, a ninth switch, a tenth switch, an eleventh switch, and a twelfth switch;

[0027] One end of the third filter capacitor is connected to the positive terminal of the high-voltage battery; one end of the fourth filter capacitor is connected to the negative terminal of the high-voltage battery; the other end of the third filter capacitor is connected to the other end of the fourth filter capacitor; the collectors of the seventh, ninth, and eleventh switching transistors are all connected to the positive terminal of the high-voltage battery; the emitters of the eighth, tenth, and twelfth switching transistors are all connected to the negative terminal of the high-voltage battery; the emitter of the seventh switching transistor and the collector of the eighth switching transistor are both connected to the first terminal of the air pump motor; the emitter of the ninth switching transistor and the collector of the tenth switching transistor are both connected to the second terminal of the air pump motor; the emitter of the eleventh switching transistor and the collector of the twelfth switching transistor are both connected to the third terminal of the air pump motor.

[0028] Optionally, the low-voltage DC / DC module includes: a fifth filter capacitor, a sixth filter capacitor, a thirteenth switch, a fourteenth switch, a fifteenth switch, a sixteenth switch, a first rectifier diode, a second rectifier diode, an energy storage capacitor, and a seventh filter capacitor;

[0029] One end of the fifth filter capacitor is connected to the positive terminal of the high-voltage battery; one end of the sixth filter capacitor is connected to the negative terminal of the high-voltage battery; the other end of the fifth filter capacitor is connected to the other end of the sixth filter capacitor; the collectors of the thirteenth and fifteenth switching transistors are both connected to the positive terminal of the high-voltage battery; the emitters of the fourteenth and sixteenth switching transistors are both connected to the negative terminal of the high-voltage battery; the emitter of the thirteenth switching transistor and the collector of the fourteenth switching transistor are both connected to the first terminal of the primary side of the transformer; the fifteenth... The emitter of the switching transistor and the collector of the sixteenth switching transistor are both connected to the second terminal of the primary side of the transformer; the anode of the first rectifier diode is connected to the first terminal of the secondary side of the transformer; the anode of the second rectifier diode is connected to the second terminal of the secondary side of the transformer; the cathodes of the first and second rectifier diodes are both connected to one end of the energy storage capacitor; the other end of the energy storage capacitor and one end of the seventh filter capacitor are both connected to the positive terminal of the low-voltage battery; the other end of the seventh filter capacitor is connected to the third terminal of the secondary side of the transformer and the negative terminal of the low-voltage battery, respectively.

[0030] Optionally, the PTC heating module includes: a first fuse and a first contactor; one end of the first contactor is connected to the positive terminal of the high-voltage battery; the other end of the first contactor is connected to one end of the first fuse; and the other end of the first fuse is connected to the PTC.

[0031] Optionally, the compressor control module includes: a second fuse and a second contactor; one end of the second contactor is connected to the positive terminal of the high-voltage battery; the other end of the second contactor is connected to one end of the second fuse; and the other end of the second fuse is connected to the compressor.

[0032] Optionally, it also includes a housing; the high-voltage power distribution system and the auxiliary power supply system are integrated within the housing.

[0033] According to the specific embodiments provided in this application, this application has the following technical effects:

[0034] This application provides a multi-functional power distribution unit, including: a high-voltage power distribution system and an auxiliary power supply system; the high-voltage power distribution system is used to divert the electrical energy output from the high-voltage battery and allocate the electrical energy to the drive unit and the integrated power generation module; the auxiliary power supply system includes an oil pump DC / AC module, an air pump DC / AC module, a low-voltage DC / DC module, a PTC heating module, and a compressor control module; the oil pump DC / AC module is used to convert the DC power from the high-voltage bus of the high-voltage battery into AC power and input it to the oil pump motor; the air pump DC / AC module is used to convert the DC power from the high-voltage bus of the high-voltage battery into AC power and input it to the air pump motor; the low-voltage DC / DC module is used to convert the DC power from the high-voltage bus of the high-voltage battery into low-voltage power to supply power to the low-voltage battery and low-voltage electrical equipment; the PTC heating module is used to transfer the electrical energy output from the high-voltage battery to the PTC; the compressor control module is used to transfer the electrical energy output from the high-voltage battery to the compressor. By distributing electrical energy through this multi-functional power distribution unit, the working efficiency and reliability of the electrical system are improved. Attached Figure Description

[0035] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0036] Figure 1 This is a schematic diagram of the structure of an all-in-one power distribution unit provided in an embodiment of this application;

[0037] Figure 2 A schematic diagram showing the connection between an all-in-one power distribution unit and an external device, provided in an embodiment of this application;

[0038] Figure 3 An electrical schematic diagram of a high-voltage power distribution system provided in an embodiment of this application;

[0039] Figure 4A circuit topology diagram of an oil pump DC / AC module provided in an embodiment of this application;

[0040] Figure 5 A circuit topology diagram of an air pump DC / AC module provided in an embodiment of this application;

[0041] Figure 6 A circuit topology diagram of a low-voltage DC / DC module provided in an embodiment of this application;

[0042] Figure 7 A circuit topology diagram of a PTC heating module provided in an embodiment of this application;

[0043] Figure 8 The circuit topology diagram of a compressor control module provided in an embodiment of this application is shown.

[0044] Reference numerals: 1. Power output fuse; 2. First pre-charge resistor; 3. Electric drive pre-charge contactor; 4. Electric drive contactor; 5. Pre-charge contactor; 6. Second pre-charge resistor; 7. Main positive contactor; 8. Main positive fuse; 9. First fuse; 10. First contactor; 11. Second fuse; 12. Second contactor. Detailed Implementation

[0045] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0046] To make the above-mentioned objectives, features and advantages of this application more apparent and understandable, the application will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0047] In one exemplary embodiment, such as Figure 1 and Figure 2 As shown, an all-in-one power distribution unit is provided, including: a high-voltage power distribution system and an auxiliary power supply system.

[0048] The high-voltage power distribution system is used to divert the electrical energy output from the high-voltage battery and allocate the electrical energy to the drive unit and the integrated power generation module.

[0049] The high-voltage power distribution system includes a first pre-charging circuit, a power output fuse 1, a second pre-charging circuit, and a main positive fuse 8; one end of the first pre-charging circuit is connected to the first end of the high-voltage battery; the other end of the first pre-charging circuit is connected to one end of the power output fuse 1; the other end of the power output fuse 1 is connected to the drive unit; one end of the second pre-charging circuit is connected to the first end of the high-voltage battery; the other end of the second pre-charging circuit is connected to one end of the main positive fuse 8; the other end of the main positive fuse 8 is connected to the integrated power generation module.

[0050] In practical applications, the electrical schematic diagram of a high-voltage power distribution system is as follows: Figure 3 As shown.

[0051] The first pre-charging circuit includes: a first pre-charging resistor 2, an electrically driven pre-charging contactor 3, and an electrically driven contactor 4.

[0052] One end of the electric drive precharge contactor 3 and one end of the electric drive contactor 4 are both connected to the first end of the high-voltage battery; the other end of the electric drive precharge contactor 3 is connected to one end of the first precharge resistor 2; the other end of the first precharge resistor 2 and the other end of the electric drive contactor 4 are both connected to one end of the power output fuse 1.

[0053] The second pre-charging circuit includes: a pre-charging contactor 5, a main positive contactor 7, and a second pre-charging resistor 6.

[0054] One end of the precharge contactor 5 and one end of the main positive contactor 7 are both connected to the first end of the high-voltage battery; the other end of the precharge contactor 5 is connected to one end of the second precharge resistor 6; the other end of the second precharge resistor 6 and the other end of the main positive contactor 7 are both connected to one end of the main positive fuse 8.

[0055] The high-voltage power distribution system primarily shunts power from the power source and the high-voltage busbar of the high-voltage battery, allocating electrical energy to the power output unit. It mainly includes a pre-charging circuit, main circuit, manual maintenance switch, and power output. In the system, contactors are driven by I / O signals from the VCU (Vehicle Control Unit) chip to control the circuit's on / off state. The power output is connected to power output fuse 1 to prevent damage to components due to excessive current. If power output is required, a parallel interface between the pre-charging circuit and the braking unit is provided for pre-charging the electric drive system and for regenerative braking.

[0056] Figure 3The first pre-charging resistor 2, the electrically driven pre-charging contactor 53, and the electrically driven contactor 4 constitute a pre-charging circuit, while the pre-charging contactor 5, the main positive contactor 7, and the second pre-charging resistor 6 constitute another pre-charging circuit. The pre-charging circuit primarily prevents damage to the contactors and fuses caused by the instantaneous large current generated by the high voltage and large capacitance on the line during power-up. Upon power-up, the pre-charging relay is engaged first, and the main relay is engaged after a certain period. The pre-charging circuit provides system safety protection, mainly preventing damage to the circuit from prolonged overload and instantaneous super-large current. This is achieved through the VCU chip's judgment of current sampling results and the fuse. For short-term overload currents, the main control chip does not react within the allowable overload range. If the overload time is too long, the VCU chip disconnects the contactor via I / O signals to ensure device safety; for instantaneous super-large currents, the fuse protects critical components.

[0057] The auxiliary power supply system includes an oil pump DC / AC module, an air pump DC / AC module, a low-voltage DC / DC module, a PTC heating module, and a compressor control module.

[0058] The oil pump DC / AC module is used to convert the DC power from the high-voltage bus of the high-voltage battery into AC power and input it to the oil pump motor.

[0059] As an optional implementation, the oil pump DC / AC module includes: a first filter capacitor, a second filter capacitor, a first switch, a second switch, a third switch, a fourth switch, a fifth switch, and a sixth switch.

[0060] One end of the first filter capacitor is connected to the positive terminal of the high-voltage battery; one end of the second filter capacitor is connected to the negative terminal of the high-voltage battery; the other ends of the first filter capacitor and the other ends of the second filter capacitor are connected; the collectors of the first, third, and fifth switching transistors are all connected to the positive terminal of the high-voltage battery; the emitters of the second, fourth, and sixth switching transistors are all connected to the negative terminal of the high-voltage battery; the emitter of the first switching transistor and the collector of the second switching transistor are both connected to the first terminal of the oil pump motor; the emitter of the third switching transistor and the collector of the fourth switching transistor are both connected to the second terminal of the oil pump motor; the emitter of the fifth switching transistor and the collector of the sixth switching transistor are both connected to the third terminal of the oil pump motor.

[0061] In practical applications, for the oil pump DC / AC module, the VCU provides the oil pump's on / off signal via the CAN bus. Fault information is collected and assessed by the MCU, which then implements appropriate protection measures and transmits the fault information back to the VCU via the CAN bus. The oil pump motor is a permanent magnet synchronous motor, requiring no specific speed or torque control; a sensorless control method is employed. The circuit topology of the oil pump DC / AC module is shown below. Figure 4 As shown, C1 and C2 are input-side filter capacitors (i.e., the first filter capacitor and the second filter capacitor); S1 to S6 are the first to sixth switching transistors, which together form a three-phase bridge inverter circuit.

[0062] The air pump DC / AC module is used to convert the DC power from the high-voltage bus of the high-voltage battery into AC power and input it to the air pump motor.

[0063] As an optional implementation, the air pump DC / AC module includes: a third filter capacitor, a fourth filter capacitor, a seventh switch, an eighth switch, a ninth switch, a tenth switch, an eleventh switch, and a twelfth switch.

[0064] One end of the third filter capacitor is connected to the positive terminal of the high-voltage battery; one end of the fourth filter capacitor is connected to the negative terminal of the high-voltage battery; the other end of the third filter capacitor is connected to the other end of the fourth filter capacitor; the collectors of the seventh, ninth, and eleventh switching transistors are all connected to the positive terminal of the high-voltage battery; the emitters of the eighth, tenth, and twelfth switching transistors are all connected to the negative terminal of the high-voltage battery; the emitter of the seventh switching transistor and the collector of the eighth switching transistor are both connected to the first terminal of the air pump motor; the emitter of the ninth switching transistor and the collector of the tenth switching transistor are both connected to the second terminal of the air pump motor; the emitter of the eleventh switching transistor and the collector of the twelfth switching transistor are both connected to the third terminal of the air pump motor.

[0065] In practical applications, the control of the air pump DC / AC module is similar to that of the oil pump motor. Switching signals are provided by the VCU via the CAN bus. Fault information is collected and judged by the MCU. After the MCU implements protection, it transmits the fault information back to the VCU via the CAN bus. The air pump motor also uses a sensorless control mode. The circuit topology of the air pump DC / AC module is shown below. Figure 5 As shown, C3 and C4 are input-side filter capacitors (i.e., the third and fourth filter capacitors); S7 to S12 are the seventh to twelfth switching transistors, which together form a three-phase bridge inverter circuit.

[0066] The low-voltage DC / DC module is used to convert the high-voltage bus DC power of the high-voltage battery into low-voltage power to supply power to the low-voltage battery and low-voltage electrical equipment.

[0067] As an optional implementation, the low-voltage DC / DC module includes: a fifth filter capacitor, a sixth filter capacitor, a thirteenth switch, a fourteenth switch, a fifteenth switch, a sixteenth switch, a first rectifier diode, a second rectifier diode, an energy storage capacitor, and a seventh filter capacitor.

[0068] One end of the fifth filter capacitor is connected to the positive terminal of the high-voltage battery; one end of the sixth filter capacitor is connected to the negative terminal of the high-voltage battery; the other end of the fifth filter capacitor is connected to the other end of the sixth filter capacitor; the collectors of the thirteenth and fifteenth switching transistors are both connected to the positive terminal of the high-voltage battery; the emitters of the fourteenth and sixteenth switching transistors are both connected to the negative terminal of the high-voltage battery; the emitter of the thirteenth switching transistor and the collector of the fourteenth switching transistor are both connected to the first terminal of the primary side of the transformer; the fifteenth... The emitter of the switching transistor and the collector of the sixteenth switching transistor are both connected to the second terminal of the primary side of the transformer; the anode of the first rectifier diode is connected to the first terminal of the secondary side of the transformer; the anode of the second rectifier diode is connected to the second terminal of the secondary side of the transformer; the cathodes of the first and second rectifier diodes are both connected to one end of the energy storage capacitor; the other end of the energy storage capacitor and one end of the seventh filter capacitor are both connected to the positive terminal of the low-voltage battery; the other end of the seventh filter capacitor is connected to the third terminal of the secondary side of the transformer and the negative terminal of the low-voltage battery, respectively.

[0069] In practical applications, for low-voltage DC / DC modules, the high-voltage side is the high-voltage DC bus, and the low-voltage side is the low-voltage DC bus. Low-voltage DC / DC modules use the CAN protocol to communicate with the VCU. A schematic diagram of the low-voltage DC / DC module circuit topology is shown below. Figure 6 As shown, C5 and C6 are the input-side filter capacitors (i.e., the fifth and sixth filter capacitors), used to suppress input voltage ripple; S13 to S16 are the thirteenth to fourteenth switching transistors, which together form a full-bridge switching converter to convert DC power into high-frequency AC power input to the primary side of the transformer; D1 and D2 are the rectifier diodes and the second rectifier diode, respectively, which rectify the AC power after the transformer step-down to DC power; L is the energy storage capacitor, and C7 is the output-side filter capacitor (the seventh filter capacitor). Together, they form a filter circuit to make the output voltage smoother.

[0070] The PTC heating module is used to transfer the electrical energy output from the high-voltage battery to the PTC heater. PTC stands for Positive Temperature Coefficient, which in this context refers to a positive temperature coefficient thermistor (such as a positive temperature coefficient thermistor).

[0071] In one optional implementation, the PTC heating module includes: a first fuse 9 and a first contactor 10; one end of the first contactor 10 is connected to the positive terminal of the high-voltage battery; the other end of the first contactor 10 is connected to one end of the first fuse 9; and the other end of the first fuse 9 is connected to the PTC.

[0072] In practical applications, such as Figure 7 As shown, the PTC heating module is powered from the high-voltage DC bus. The power supply interface is equipped with a PTC fuse (i.e., the first fuse 9) and a PTC contactor (i.e., the first contactor 10).

[0073] The compressor control module is used to transmit the electrical energy output by the high-voltage battery to the compressor.

[0074] In one optional implementation, the compressor control module includes: a second fuse 11 and a second contactor 12; one end of the second contactor 12 is connected to the positive terminal of the high-voltage battery; the other end of the second contactor 12 is connected to one end of the second fuse 11; and the other end of the second fuse 11 is connected to the compressor.

[0075] In practical applications, such as Figure 8 As shown, the compressor control module has its own controller. It is powered by the high-voltage DC bus, and the power supply interface is equipped with a compressor fuse (second fuse 11) and a compressor contactor (i.e., second contactor 12).

[0076] As an optional implementation, it also includes a housing; the high-voltage power distribution system and the auxiliary power supply system are integrated within the housing.

[0077] In practical applications, the all-in-one power distribution unit described in this application integrates all its components into an electrical box (body). High-power lines within the electrical box are connected using copper busbars, while control lines, signal lines, and low-voltage power supply lines are connected using shielded cables. A water channel is provided at the bottom of the electrical box for heat dissipation of power devices and switching transistors. The high-voltage DC power from the high-voltage battery passes through the electrical drive contactor 4 and connects to the electric drive pre-charge circuit and electric drive module respectively. After passing through the circuit breaker and pre-charge circuit, it is connected to the high-voltage DC bus. A parallel circuit interface is then set on the bus to connect the range extender, PTC heating module, compressor control module, drive unit, low-voltage DC / DC module, oil pump DC / DC module, and air pump DC / DC module for electrical distribution. The power source system is directly connected to the high-voltage bus in parallel via an interface; contactors and fuses are installed on the parallel interfaces of the PTC heating module and compressor control module; fuses are installed on the parallel interfaces of the low-voltage DC / DC module, oil pump DC / AC module, and air pump DC / AC module.

[0078] This application's all-in-one power distribution unit is designed with high integration as its goal, mainly consisting of a high-voltage power distribution system and an auxiliary power supply system. The high-voltage power distribution system mainly includes sub-modules such as power distribution, pre-charging circuit, current acquisition, and safety protection. The auxiliary power supply system mainly includes an oil pump DC / AC module, an air pump DC / AC module, a low-voltage DC / DC module, a PTC heating module, and a compressor control module. The integration design between the various modules of the system is as follows: Figure 2 As shown. The various modules are integrated through mechanical, electrical, and control coupling, working collaboratively to supply power to the vehicle's electrical equipment. The system composition and component functions are detailed below:

[0079] (1) The power distribution module controls the power transmission by controlling the contactor action according to the vehicle instructions.

[0080] (2) The pre-charging circuit module is responsible for the pre-charging process when the system is powered on.

[0081] (3) The current acquisition module is responsible for acquiring the current of each power high-voltage line, converting the current signal into an analog quantity and transmitting it to the control system. After receiving the current data from the current acquisition module, the control system processes and analyzes the current information, monitors the working status of each high-voltage line in the entire system, determines whether each electrical device is working properly, and takes timely protective measures or adjustment mechanisms when the current is abnormal or changes.

[0082] (4) The safety protection module provides overcurrent protection for the high-voltage power line through contactors and fuses, and stops power supply when the power is abnormal.

[0083] (5) The oil pump DC / AC module and the air pump DC / AC module are responsible for converting the high-voltage bus DC power of the battery into AC power required for motor drive, and controlling the oil pump motor and air pump motor by controlling the power electronic devices of DC / AC.

[0084] (6) The low-voltage DC / DC module is responsible for converting the high-voltage bus DC power into low-voltage power to replenish the vehicle's low-voltage battery and drive low-voltage electrical equipment.

[0085] (7) The PTC heating module and the compressor control module mainly reserve power interfaces, and transmit the power required by the PTC and the compressor to the PTC and the compressor through contactors.

[0086] The system's interface design mainly includes mechanical interfaces, electrical interfaces, and control interfaces. The descriptions of each interface are as follows:

[0087] The mechanical interface mainly involves fixing the electrical box to the vehicle. This is achieved by using pre-drilled fixing holes on the bottom edge of the box and bolts to secure it to the chassis. Rubber pads are installed between the box and the chassis for vibration damping.

[0088] Electrical interfaces mainly include high-voltage interfaces and low-voltage interfaces. High-voltage interfaces primarily include those outputting high-voltage DC power to the electric drive system, high-voltage DC power to the PTC, high-voltage DC power to the compressor, high-voltage AC power to the oil pump, and high-voltage AC power to the air pump. Low-voltage interfaces primarily include those outputting low-voltage power externally.

[0089] The control interfaces are divided into two categories based on the signals required by the system. The first category consists of control commands from the vehicle and status feedback signals from the system to the vehicle. The system also provides a fault self-diagnosis interface protocol to facilitate system maintenance. The control interface between the system and the outside world uses a CAN bus, and the communication control interface is designed according to the CAN bus protocol. The second category consists of low-voltage control power supply signals, which provide low-voltage control power to the main control board.

[0090] The multi-functional power distribution unit of this application provides low-voltage power to the high-voltage power distribution system and auxiliary power supply system from a low-voltage battery before system startup. After system startup, the system's DC / DC converter starts working, charging the battery and ensuring stable low-voltage DC bus voltage. Signal acquisition, transmission, and reception between modules are communicated via a CAN bus. For cooling design, the system's cooling water circuit primarily cools the power electronic devices on the DC / AC and DC / DC converters. The high-voltage auxiliary power distribution system requires a water flow rate of 26 L / min and an inlet temperature not exceeding 55 degrees Celsius.

[0091] The multi-in-one power distribution unit of this application has the following technical features:

[0092] 1. The all-in-one power distribution unit of this application achieves a highly integrated design, effectively improving the system's efficiency and reliability. This application emphasizes modular integration and a coupled collaborative mechanism, highly integrating the high-voltage power distribution system and auxiliary power supply system into a single electrical box. Each module works collaboratively through mechanical, electrical, and control coupling. This highly integrated design reduces the complexity of external wiring and independent operation of multiple systems, lowers signal transmission loss and interface failure rates, simplifies wiring and maintenance requirements, and improves the operating efficiency and reliability of the electrical system.

[0093] 2. The all-in-one power distribution unit of this application is equipped with comprehensive multi-layered safety protection mechanisms. The system is equipped with a pre-charging circuit and a safety protection module. The pre-charging circuit effectively avoids instantaneous high-current surges during power-on by engaging a pre-charging relay, while the fuse provides instantaneous ultra-high current protection for critical components. Simultaneously, the main control chip samples and judges the current, providing real-time overload protection. These multiple safety protection mechanisms ensure the safety and stability of the electrical distribution unit under complex operating conditions.

[0094] 3. The multi-functional power distribution unit of this application adopts a modular design, which facilitates maintenance. The modules of the multi-functional power distribution unit are designed to be independent of each other, but functionally coupled. When a module fails, it can be quickly troubleshooted and repaired without affecting other modules, making the maintenance of the device itself easier.

[0095] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0096] This document uses specific examples to illustrate the principles and implementation methods of this application. The descriptions of the above embodiments are only for the purpose of helping to understand the methods and core ideas of this application. Furthermore, those skilled in the art will recognize that, based on the ideas of this application, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of this application.

Claims

1. A multi-functional power distribution unit, characterized in that, include: High-voltage power distribution system and auxiliary power supply system; The high-voltage power distribution system is used to divert the electrical energy output from the high-voltage battery and allocate the electrical energy to the drive unit and the integrated power generation module. The high-voltage power distribution system includes a first pre-charging circuit, a power output fuse, a second pre-charging circuit, and a main positive fuse; one end of the first pre-charging circuit is connected to the first end of the high-voltage battery; the other end of the first pre-charging circuit is connected to one end of the power output fuse; the other end of the power output fuse is connected to a drive unit; one end of the second pre-charging circuit is connected to the first end of the high-voltage battery; the other end of the second pre-charging circuit is connected to one end of the main positive fuse; the other end of the main positive fuse is connected to an integrated power generation module. The auxiliary power supply system includes an oil pump DC / AC module, an air pump DC / AC module, a low-voltage DC / DC module, a PTC heating module, and a compressor control module; The oil pump DC / AC module is used to convert the DC power from the high-voltage bus of the high-voltage battery into AC power and input it to the oil pump motor. The air pump DC / AC module is used to convert the DC power from the high-voltage bus of the high-voltage battery into AC power and input it to the air pump motor. The low-voltage DC / DC module is used to convert the high-voltage bus DC power of the high-voltage battery into low-voltage power to supply power to the low-voltage battery and low-voltage electrical equipment. The PTC heating module is used to transmit the electrical energy output by the high-voltage battery to the PTC heater; The compressor control module is used to transmit the electrical energy output by the high-voltage battery to the compressor.

2. The all-in-one power distribution unit according to claim 1, characterized in that, The first pre-charge circuit includes: a first pre-charge resistor, an electrically driven pre-charge contactor, and an electrically driven contactor; One end of the electric drive precharge contactor and the other end of the electric drive contactor are both connected to the first end of the high-voltage battery; the other end of the electric drive precharge contactor is connected to one end of the first precharge resistor; the other end of the first precharge resistor and the other end of the electric drive contactor are both connected to one end of the power output fuse.

3. The all-in-one power distribution unit according to claim 1, characterized in that, The second pre-charge circuit includes: a pre-charge contactor, a main positive contactor, and a second pre-charge resistor; One end of the precharge contactor and one end of the main positive contactor are both connected to the first end of the high-voltage battery; the other end of the precharge contactor is connected to one end of the second precharge resistor; the other end of the second precharge resistor and the other end of the main positive contactor are both connected to one end of the main positive fuse.

4. The all-in-one power distribution unit according to claim 1, characterized in that, The oil pump DC / AC module includes: a first filter capacitor, a second filter capacitor, a first switching transistor, a second switching transistor, a third switching transistor, a fourth switching transistor, a fifth switching transistor, and a sixth switching transistor; One end of the first filter capacitor is connected to the positive terminal of the high-voltage battery; one end of the second filter capacitor is connected to the negative terminal of the high-voltage battery; the other ends of the first filter capacitor and the other ends of the second filter capacitor are connected; the collectors of the first, third, and fifth switching transistors are all connected to the positive terminal of the high-voltage battery; the emitters of the second, fourth, and sixth switching transistors are all connected to the negative terminal of the high-voltage battery; the emitter of the first switching transistor and the collector of the second switching transistor are both connected to the first terminal of the oil pump motor; the emitter of the third switching transistor and the collector of the fourth switching transistor are both connected to the second terminal of the oil pump motor; the emitter of the fifth switching transistor and the collector of the sixth switching transistor are both connected to the third terminal of the oil pump motor.

5. The all-in-one power distribution unit according to claim 1, characterized in that, The air pump DC / AC module includes: a third filter capacitor, a fourth filter capacitor, a seventh switch, an eighth switch, a ninth switch, a tenth switch, an eleventh switch, and a twelfth switch. One end of the third filter capacitor is connected to the positive terminal of the high-voltage battery; one end of the fourth filter capacitor is connected to the negative terminal of the high-voltage battery; the other end of the third filter capacitor is connected to the other end of the fourth filter capacitor; the collectors of the seventh, ninth, and eleventh switching transistors are all connected to the positive terminal of the high-voltage battery; the emitters of the eighth, tenth, and twelfth switching transistors are all connected to the negative terminal of the high-voltage battery; the emitter of the seventh switching transistor and the collector of the eighth switching transistor are both connected to the first terminal of the air pump motor; the emitter of the ninth switching transistor and the collector of the tenth switching transistor are both connected to the second terminal of the air pump motor; the emitter of the eleventh switching transistor and the collector of the twelfth switching transistor are both connected to the third terminal of the air pump motor.

6. The all-in-one power distribution unit according to claim 1, characterized in that, The low-voltage DC / DC module includes: a fifth filter capacitor, a sixth filter capacitor, a thirteenth switch, a fourteenth switch, a fifteenth switch, a sixteenth switch, a first rectifier diode, a second rectifier diode, an energy storage capacitor, and a seventh filter capacitor; One end of the fifth filter capacitor is connected to the positive terminal of the high-voltage battery; one end of the sixth filter capacitor is connected to the negative terminal of the high-voltage battery; the other end of the fifth filter capacitor is connected to the other end of the sixth filter capacitor; the collectors of the thirteenth and fifteenth switching transistors are both connected to the positive terminal of the high-voltage battery; the emitters of the fourteenth and sixteenth switching transistors are both connected to the negative terminal of the high-voltage battery; the emitter of the thirteenth switching transistor and the collector of the fourteenth switching transistor are both connected to the first terminal of the primary side of the transformer; the fifteenth... The emitter of the switching transistor and the collector of the sixteenth switching transistor are both connected to the second terminal of the primary side of the transformer; the anode of the first rectifier diode is connected to the first terminal of the secondary side of the transformer; the anode of the second rectifier diode is connected to the second terminal of the secondary side of the transformer; the cathodes of the first and second rectifier diodes are both connected to one end of the energy storage capacitor; the other end of the energy storage capacitor and one end of the seventh filter capacitor are both connected to the positive terminal of the low-voltage battery; the other end of the seventh filter capacitor is connected to the third terminal of the secondary side of the transformer and the negative terminal of the low-voltage battery, respectively.

7. The all-in-one power distribution unit according to claim 1, characterized in that, The PTC heating module includes: a first fuse and a first contactor; one end of the first contactor is connected to the positive terminal of the high-voltage battery; the other end of the first contactor is connected to one end of the first fuse; and the other end of the first fuse is connected to the PTC.

8. The all-in-one power distribution unit according to claim 1, characterized in that, The compressor control module includes: a second fuse and a second contactor; one end of the second contactor is connected to the positive terminal of the high-voltage battery; the other end of the second contactor is connected to one end of the second fuse; and the other end of the second fuse is connected to the compressor.

9. The all-in-one power distribution unit according to claim 1, characterized in that, It also includes a housing; the high-voltage power distribution system and the auxiliary power supply system are integrated within the housing.

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