Power supply control device and power supply system

Abstract

The utility model provides a power supply control device and a power supply system. The power supply control device provided by the embodiment of the utility model comprises a box body, wherein the box body is provided with an accommodating cavity with an opening at one end; the converter module comprises an alternating current-direct current conversion module, a voltage transformation module and a first electric connecting piece; the AC / DC conversion module is provided with a first input / output interface and a second input / output interface; the voltage transformation module is provided with a third input / output interface and a fourth input / output interface; the first electric connecting piece is electrically connected with the first input / output interface and is used for accessing an external power supply; the second input / output interface is electrically connected with the third input / output interface; and the cover body is arranged at the opening of the box body and is used for sealing the accommodating cavity, the cover body is provided with an open window, and the open window is arranged corresponding to the first electric connecting piece. The power supply control device provided by the utility model can be better convenient to mount and dissipate heat, and is beneficial to miniaturization and light-weight design.

Description

Technical Field

[0001] This application relates to the field of power supply system technology, specifically to a power control device and a power supply system. Background Technology

[0002] In related technologies, highly integrated design of various core components of new energy vehicles can reduce the cost of these components, improve their performance, enable lightweight design, and reduce the overall energy consumption ratio of the vehicle. One approach involves integrating the high-low voltage DC-DC converter (DCDC) and the on-board charger (OBC) into a multi-functional electric drive system, installed inside the vehicle, and transmitting power through corresponding connectors and wiring harnesses, while cooling is achieved through cooling pipe connectors and cooling water channels. However, it is not possible to integrate the high-low voltage DC-DC converter and the on-board charger into a standardized miniaturized module that allows for easy installation and heat dissipation, further facilitating the miniaturization and lightweight design of the OBC. Utility Model Content

[0003] This application provides a power control device that is more portable, easier to install, and has better heat dissipation, which is beneficial for miniaturization and lightweight design.

[0004] This application provides a power control device, which includes:

[0005] A housing having an accommodating cavity open at one end;

[0006] A converter module, comprising an AC / DC conversion module, a transformer module, and a first electrical connector; the AC / DC conversion module having a first input / output interface and a second input / output interface; the transformer module having a third input / output interface and a fourth input / output interface; the first electrical connector being electrically connected to the first input / output interface for connecting to an external power source; the second input / output interface being electrically connected to the third input / output interface; and...

[0007] A cover is disposed at the opening of the housing to close the accommodating cavity. The cover has a window, which is provided corresponding to the first electrical connector.

[0008] In a further embodiment, the converter module further includes a circuit board and a first fastener. The circuit board is used to mount the converter module. The first electrical connector includes a first plug-in portion, a first connecting portion, and a first socket portion that are bent and connected in sequence. The first plug-in portion and the first socket portion are bent toward the same side relative to the first connecting portion. The first plug-in portion is inserted into the circuit board. The first connecting portion has a first through hole for inserting the first fastener to electrically connect the first electrical connector to the first input / output interface. The first socket portion has a first sleeve hole for inserting a cable to connect to an external power source.

[0009] In a further embodiment, the converter module further includes a second fastener and a second electrical connector. The second electrical connector includes a second plug portion, a second connecting portion, and a second socket portion that are bent and connected in sequence. The second plug portion and the second socket portion are bent toward the same side relative to the second connecting portion. The second plug portion is plugged into the circuit board. The second connecting portion has a second through hole for passing through the second fastener to electrically connect the second electrical connector to the second input / output interface. The second socket portion has a second sleeve hole for passing through a cable to electrically connect the third input / output interface.

[0010] In a further embodiment, the converter module further includes a connector electrically connected to the fourth input / output interface, the connector passing through the side wall of the housing and protruding from the outside of the housing.

[0011] In a further embodiment, the AC / DC conversion module further includes a first filter, a conversion unit, and a second filter connected in series. The first filter is electrically connected to the first input / output interface and is used to filter the AC / DC signals entering and exiting the conversion unit. The conversion unit is used to convert AC signals and DC signals. The second filter is electrically connected to the second input / output interface and is used to filter the AC / DC signals entering and exiting the conversion unit.

[0012] In a further embodiment, the converter module further includes control terminals, which are electrically connected to the first input / output interface and the second input / output interface respectively, for controlling the input and output of the AC / DC conversion module.

[0013] In a further embodiment, the power control device further includes an isolation plate located within the receiving cavity, with the AC / DC conversion module and the transformer module respectively disposed on opposite sides of the isolation plate, the AC / DC conversion module being disposed closer to the cover than the transformer module.

[0014] In a further embodiment, the housing includes a bent and connected bottom plate and side plates. The side plates are arranged around the outer periphery of the bottom plate, and the bottom plate and the side plates form the accommodating cavity. The cover is disposed on the side of the side plate away from the bottom plate and connected to the side plate. The bottom plate has a cooling channel, a first channel opening, and a second channel opening. The cooling channel is located inside the bottom plate. The first channel opening and the second channel opening are respectively connected to opposite ends of the cooling channel. The first channel opening and the second channel opening respectively penetrate the surface of the bottom plate away from the cover. The first channel opening and the second channel opening are used to connect to an external cooling system. The housing also includes a first sealing ring and a second sealing ring. The first sealing ring is disposed at the first channel opening and protrudes from the surface of the bottom plate away from the cover. The second sealing ring is disposed at the second channel opening and protrudes from the surface of the bottom plate away from the cover.

[0015] In a further embodiment, the housing further includes a plurality of mounting portions and a positioning portion. The plurality of mounting portions are arranged around the outer periphery of the base plate for mounting the housing to an external cooling system so that the first flow channel and the second flow channel communicate with the external cooling system. The positioning portion is arranged on the side of the base plate away from the cover and is used to pass through the external cooling system to position the relative position of the housing and the external cooling system.

[0016] Furthermore, this application embodiment also provides a power supply system, the power supply system comprising:

[0017] Battery module; and

[0018] The power control device described in this application embodiment is electrically connected to the battery module and is used to control the charging and discharging of the battery module.

[0019] The power control device of this application embodiment includes a housing with an open cavity at one end; a converter module including an AC / DC conversion module, a transformer module, and a first electrical connector; the AC / DC conversion module having a first input / output interface and a second input / output interface; the transformer module having a third input / output interface and a fourth input / output interface; the first electrical connector being electrically connected to the first input / output interface for connecting to an external power source; the second input / output interface being electrically connected to the third input / output interface; and a cover disposed at the opening of the housing for sealing the cavity, the cover having a window corresponding to the first electrical connector. The power control device integrates the AC / DC conversion module and the transformer module, both of which are disposed within the cavity, facilitating full utilization of the cavity's space and achieving integrated design. When the AC / DC converter module and the transformer module are assembled into the battery system, compared to a scheme where the AC / DC converter module and the transformer module are respectively housed in a separate enclosure, the power control device provided in this application helps save space occupied by the battery system, improves space utilization, and facilitates the miniaturization design of the battery system. Furthermore, the multi-functional integrated power control device connects directly to corresponding functional components via wiring harnesses, reducing the connection of input, output, and control connectors, thereby reducing the overall vehicle weight and manufacturing cost. Moreover, the power control device can serve as a standard miniaturized module that is easy to install and dissipate heat, facilitating installation and connection with multi-in-one electric drive systems or power battery CTCs in new energy vehicles. Attached Figure Description

[0020] To more clearly illustrate the technical solutions of the embodiments of this application, 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.

[0021] Figure 1 This is a schematic diagram of the structure of a power control device according to an embodiment of this application.

[0022] Figure 2 This is an exploded structural diagram of a power control device according to an embodiment of this application.

[0023] Figure 3 This application Figure 2 Enlarged structural diagram of dashed box I.

[0024] Figure 4 This is an exploded structural diagram of the first electrical connector according to an embodiment of this application.

[0025] Figure 5 This application Figure 2 Enlarged structural diagram of dashed box II.

[0026] Figure 6 This is an exploded structural diagram of the second electrical connector according to an embodiment of this application.

[0027] Figure 7 This is a schematic diagram of the power control device according to another embodiment of this application.

[0028] Figure 8 This is a schematic diagram of the structure of a converter module according to an embodiment of this application.

[0029] Figure 9 This is a partial structural schematic diagram of a power control device according to another embodiment of this application.

[0030] Figure 10 This application describes a power control device according to an embodiment of the power control device. Figure 7 A schematic diagram of the cross-sectional structure along the AA direction.

[0031] Figure 11 This application describes a power control device according to an embodiment of the power control device. Figure 7 Schematic diagram of the cross-sectional structure in the middle BB direction.

[0032] Figure 12 This application describes a power control device according to an embodiment of the power control device. Figure 7 A schematic diagram of the cross-sectional structure along the CC direction.

[0033] Figure 13 This is a schematic diagram of the power control device according to another embodiment of this application.

[0034] Figure 14 This is a partial exploded structural diagram of a power control device according to another embodiment of this application.

[0035] Figure 15 This is a schematic diagram of the structure of a power control device and an external cooling system in another embodiment of this application.

[0036] Figure 16 This is a schematic diagram of the structure of a power supply system according to an embodiment of this application.

[0037] Figure 17 This is a structural schematic diagram of the vehicle according to an embodiment of this application.

[0038] Explanation of reference numerals in the attached figures:

[0039] 100-Power control device, 10-Casing, 11-Accommodation cavity, 12-Base plate, 13-Side plate, 121-Cooling channel, 122-First channel opening, 123-Second channel opening, 14-External cooling system, 15-First sealing ring, 16-Second sealing ring, 17-Mounting part, 18-Positioning part, 20-Converter module, 21-AC / DC conversion module, 211-First input / output interface, 212-Second input / output interface, 213-First filter, 214-Conversion unit, 215-Second filter, 22-Transformer module, 221-Third input / output interface, 222-Fourth input / output interface, 23-First electrical connector, 2 31-First plug-in part, 232-First connecting part, 2321-First through hole, 233-First socket part, 2331-First socket hole, 24-Circuit board, 25-First fastener, 26-Second fastener, 27-Second electrical connector, 271-Second plug-in part, 272-Second connecting part, 2721-Second through hole, 273-Second socket part, 2731-Second socket hole, 28-Plug-in interface, 29-Control terminal, 30-Cover, 31-Window, 40-Isolation plate, 41-First isolation part, 42-Second isolation part, 43-Third isolation part, 1000-Power supply system, 200-Vehicle, 210-Vehicle body, 220-Battery module. Detailed Implementation

[0040] To enable those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present application, and not all embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present application.

[0041] The terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish different objects, not to describe a specific order. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or apparatus that includes a series of steps or units is not limited to the listed steps or units, but may optionally include steps or units not listed, or may optionally include other steps or units inherent to these processes, methods, products, or apparatuses.

[0042] The technical solutions in the embodiments of this application will now be described with reference to the accompanying drawings.

[0043] It should be noted that, for ease of explanation, the same reference numerals denote the same components in the embodiments of this application, and for the sake of brevity, detailed descriptions of the same components are omitted in different embodiments.

[0044] In related technologies, highly integrated design of various core components of new energy vehicles can reduce the cost of these components, improve their performance, enable lightweight design, and reduce the overall energy consumption ratio of the vehicle. One approach involves integrating the high-low voltage DC-DC converter (DCDC) and the on-board charger (OBC) into a multi-functional electric drive system, installed inside the vehicle, and transmitting power through corresponding connectors and wiring harnesses, while cooling is achieved through cooling pipe connectors and cooling water channels. However, it is not possible to integrate the high-low voltage DC-DC converter and the on-board charger into a standardized, miniaturized module that allows for easy installation and heat dissipation.

[0045] Please see Figure 1 and Figure 2 This application provides a power control device 100, which includes: a housing 10, a converter module 20, and a cover 30. The housing 10 has an accommodating cavity 11 with one end open; the converter module 20 includes an AC / DC conversion module 21, a transformer module 22, and a first electrical connector 23; the AC / DC conversion module 21 has a first input / output interface 211 and a second input / output interface 212; the transformer module 22 has a third input / output interface 221 and a fourth input / output interface 222; the first electrical connector 23 is electrically connected to the first input / output interface 211 for connecting to an external power source; the second input / output interface 212 is electrically connected to the third input / output interface 221; the cover 30 is disposed at the opening of the housing 10 for closing the accommodating cavity 11, and the cover 30 has a window 31, which is disposed corresponding to the first electrical connector 23.

[0046] In some embodiments, the power control device 100 can control both the battery module 220 (e.g., ...) Figure 15 (As shown) It can be charged and can also convert high-voltage DC to low-voltage DC through transformer module 22, which is responsible for drawing power from battery module 220 to power vehicle electrical equipment.

[0047] Optionally, the AC / DC conversion module 21 can be, but is not limited to, an on-board charger (OBC), which is used to convert AC power output from the external power grid into DC power to charge the battery module 220.

[0048] Optionally, the transformer module 22 can be, but is not limited to, a high-low voltage DC-DC converter (DCDC). Specifically, the transformer module 22 can step down high-voltage DC to low-voltage DC, and the converter module can also step up low-voltage DC to high-voltage DC. Optionally, the high-low voltage DC-DC converter is used to convert the high-voltage DC output from the vehicle charger into low-voltage DC for charging low-voltage electrical appliances or energy storage devices. In other words, the converter module 20 can boost or buck the voltage signal input to the power control device 100 to adjust the voltage to a preset value and then output it to external devices through the interface 28 of the power control device 100 to provide stable current to the external devices.

[0049] Alternatively, low-voltage electrical appliances may include vehicle lights, display instruments, air conditioners, multimedia equipment, etc.

[0050] In some embodiments, the on-board charger may be a unidirectional on-board charger or a bidirectional on-board charger.

[0051] In one specific embodiment, the on-board charger is a unidirectional on-board charger, which can be used to charge the battery module 220. The main working principle of the unidirectional on-board charger is to convert the AC input current into the high-voltage DC current required by the battery module 220. The grid voltage is connected to the unidirectional on-board charger via a ground AC charging pile, AC charging port, etc., and the battery module 220 is charged through the unidirectional on-board charger. In other words, the unidirectional on-board charger receives the externally input AC voltage and converts it into DC voltage to charge the battery module 220, thereby realizing slow charging of the battery module 220.

[0052] In one specific embodiment, the on-board charger is a bidirectional on-board charger with an inverter function. It can be used to charge the battery module 220 and also to discharge to the external device. The main working principle of the bidirectional on-board charger is to convert the AC input current into the high-voltage DC current required by the battery module 220, and to convert the high-voltage DC current output by the battery module 220 into AC output current. In other words, on the one hand, the bidirectional on-board charger receives the externally input AC voltage and converts it into DC voltage to charge the battery module 220, thereby achieving slow charging of the battery module 220; on the other hand, the bidirectional on-board charger receives the DC voltage input by the battery module 220 and converts it into AC voltage to discharge to the external interface as an emergency power source.

[0053] Understandably, the cover 30 is connected to the housing 10 to form a cavity 11 and house the converter module, thereby protecting the converter module from external moisture or dust entering the power control device 100 and damaging the converter module 20, which helps to extend the life of the converter module 20.

[0054] Understandably, the opening 31 is correspondingly arranged with the first connector, meaning that the orthographic projection of the first connector onto the surface of the cover 30 facing the first connector falls within the range of the opening 31. When the converter module 20 is connected to an external power grid, the cable can be directly connected to the first electrical connector 23 through the opening 31.

[0055] Optionally, the battery module 220 of this application may include, but is not limited to, an electric drive power assembly or a power battery CTC (Cell-to-Chassis), and the power control device 100 may include, but is not limited to, devices that can be applied to a power battery CTC or an electric drive power assembly.

[0056] When the battery module 220 is a CTC (Continuous Charged Battery) and the power control device 100 is applied to the battery pack, the CTC includes a housing, a battery, and an interface. Both the battery and the power control device 100 are housed within the housing. The first electrical connector 23 is electrically connected to the interface, which is used to connect to an external power source. The fourth input / output interface 222 is electrically connected to the battery. When the CTC is applied to the vehicle 200, the interface is used to connect to a slow-charging port on the external power grid, thereby enabling charging of the CTC.

[0057] The battery module 220 is an electric drive assembly. When the power control device 100 is applied to the electric drive assembly, the electric drive assembly housing has an interface for connecting to an external power grid. The first electrical connector 23 is electrically connected to the interface, which is used to connect to an external power source. The fourth input / output interface 222 is used to electrically connect to the battery of the electric drive assembly. When the electric drive assembly is applied to the vehicle 200, the interface is used to connect to the slow charging port of the external power grid, thereby enabling charging of the electric drive assembly.

[0058] The power control device 100 of this application embodiment includes a housing 10, the housing 10 having an accommodating cavity 11 with one end open; a converter module 20, the converter module 20 including an AC / DC conversion module 21, a transformer module 22 and a first electrical connector 23; the AC / DC conversion module 21 having a first input / output interface 211 and a second input / output interface 212; the transformer module 22 having a third input / output interface 221 and a fourth input / output interface 222; the first electrical connector 23 is electrically connected to the first input / output interface 211 for connecting to an external power source; the second input / output interface 212 is electrically connected to the third input / output interface 221; and a cover 30, the cover 30 being disposed at the opening of the housing 10 for closing the accommodating cavity 11, the cover 30 having a window 31, the window 31 being disposed corresponding to the first electrical connector 23. The power control device 100 integrates the AC / DC conversion module 21 and the transformer module 22. Both the AC / DC conversion module 21 and the transformer module 22 are housed within the accommodating cavity 11, facilitating full utilization of the cavity's space and achieving integrated design. When the AC / DC conversion module 21 and the transformer module 22 are assembled into the battery pack, compared to a separate enclosure for each module, the power control device 100 provides a more compact design by integrating them into a single unit. Furthermore, the multi-functional integrated power control device 100 connects directly to corresponding functional components via wiring harnesses, reducing the need for input, output, and control connector connections, thereby lowering vehicle weight and manufacturing costs. Moreover, the power control device 100 can serve as a standard, miniaturized module that is easy to install and dissipate heat, facilitating installation and connection with multi-functional electric drive systems or CTC power batteries in new energy vehicles.

[0059] Please see Figure 3 and Figure 4 In some embodiments, the converter module 20 further includes a circuit board 24 and a first fastener 25. The circuit board 24 is used to mount the converter module 20. The first electrical connector 23 includes a first plug-in portion 231, a first connecting portion 232, and a first socket portion 233 that are bent and connected in sequence. The first plug-in portion 231 and the first socket portion 233 are bent toward the same side relative to the first connecting portion 232. The first plug-in portion 231 is plugged into the circuit board 24. The first connecting portion 232 has a first through hole 2321 for passing through the first fastener 25 to electrically connect the first electrical connector 23 to the first input / output interface 211. The first socket portion 233 has a first sleeve hole 2331 for passing through a cable to connect to an external power source.

[0060] Optionally, there are two first electrical connectors 23. The two first electrical connectors 23 are used to electrically connect to the positive and negative terminals of an external power source, respectively.

[0061] Optionally, the first plug-in portion 231 passes through the circuit board 24 to fix the first electrical connector 23 to the converter module.

[0062] Understandably, the first fastener 25 is sequentially inserted through the first electrical connector 23 and the first input / output interface 211 to fix the first electrical connector 23 to the first input / output interface 211 and to electrically connect the first electrical connector 23 to the first input / output interface 211.

[0063] Optionally, the first electrical connector 23 can be a copper lug, copper sheet, etc.

[0064] Optionally, the first fastener 25 may be, but is not limited to, a screw, bolt, stud, etc.

[0065] Understandably, the external power source can be, but is not limited to, external power supply equipment, such as charging stations.

[0066] Optionally, the first connecting portion 232 can be, but is not limited to, a cuboid or approximately a cuboid. In the schematic diagram of this embodiment, the first connecting portion 232 is illustrated as a cuboid. It should be understood that the shape of the first connecting portion 232 should not be construed as a limitation on the first connecting portion 232 of this utility model. The first connecting portion 232 is used to fix the first electrical connector 23 to the converter module 20, thereby ensuring a stable connection between the first electrical connector 23 and the external power supply.

[0067] Optionally, the first socket portion 233 may be, but is not limited to, a cylinder or approximately a cylinder. In the schematic diagram of this embodiment, the first socket portion 233 is illustrated as a hollow cylinder. It should be understood that the shape of the first socket portion 233 should not be construed as a limitation on the first electrical connector 23 provided in this embodiment. The first socket portion 233 is used to fix the cable, pressing one end of the cable in place, thereby connecting the first electrical connector 23 to an external power source.

[0068] Optionally, the first through hole 2321 can be, but is not limited to, a circular, square or other irregularly shaped through hole. In the schematic diagram of the embodiment of this application, the first through hole 2321 is a circular through hole as an example. It can be understood that the shape of the first through hole 2321 should not be a limitation on the first electrical connector 23 provided in this embodiment.

[0069] Understandably, when the first input / output interface 211 is connected to an external power source via a cable, the first fastener 25 passes sequentially through the first connecting part 232 and the converter module 20 from the side of the converter module facing the window 31, so as to assemble the first fastener 25, the first connecting part 232, and the converter module 20 into one unit; the cable passes through the first sleeve hole 2331, and the external power source is connected to the power control device 100 via the cable.

[0070] In this embodiment, the first electrical connector 23 includes a first connecting portion 232 and a first sleeve portion 233. The first connecting portion 232 has a first through hole 2321. By cooperating with the first fastener 25, the first electrical connector 23 can be stably fixed to the converter module 20. In addition, the first sleeve portion 233 has a first sleeve hole 2331, which is used to pass through a cable, so that the external power supply can be connected to the power control device 100 through the wire harness.

[0071] Please see Figure 5 and Figure 6 In some embodiments, the converter module 20 further includes a second fastener 26 and a second electrical connector 27. The second electrical connector 27 includes a second plug portion 271, a second connecting portion 272, and a second socket portion 273 that are bent and connected in sequence. The second plug portion 271 and the second socket portion 273 are bent toward the same side relative to the second connecting portion 272. The second plug portion 271 is plugged into the circuit board 24. The second connecting portion 272 has a second through hole 2721 for passing through the second fastener 26 to electrically connect the second electrical connector 27 to the second input / output interface 212. The second socket portion 273 has a second sleeve hole 2731 for passing through a cable to electrically connect the third input / output interface 221.

[0072] Optionally, there are two second electrical connectors 27. The two second electrical connectors 27 are used to electrically connect the positive and negative terminals of the battery module 220, respectively.

[0073] Optionally, the second plug portion 271 passes through the circuit board 24 to fix the second electrical connector 27 to the converter module 20.

[0074] Understandably, the second fastener 26 is sequentially inserted through the second electrical connector 27 and the second input / output interface 212 to fix the second electrical connector 27 and the second input / output interface 212 and to electrically connect the second electrical connector 27 and the second input / output interface 212.

[0075] Optionally, the second electrical connector 27 can be a copper lug, copper sheet, etc.

[0076] Optionally, the second fastener 26 may be, but is not limited to, a screw, bolt, stud, etc.

[0077] Understandably, the battery module 220 can be, but is not limited to, a secondary battery, such as a lead-acid battery, nickel-cadmium battery, nickel-metal hydride battery, lithium-ion battery, lithium metal battery, etc.

[0078] Optionally, the second connecting portion 272 can be, but is not limited to, a cuboid or approximately a cuboid. In the schematic diagram of this embodiment, the second connecting portion 272 is illustrated as a cuboid. It should be understood that the shape of the second connecting portion 272 should not be construed as a limitation on the second connecting portion 272 of this utility model. The second connecting portion 272 is used to fix the second electrical connector 27 to the converter module 20, thereby making the second electrical connector 27 and the battery module 220 securely connected.

[0079] Optionally, the second socket portion 273 can be, but is not limited to, a cylinder or approximately a cylinder. In the schematic diagram of this embodiment, the second socket portion 273 is illustrated as a hollow cylinder. It should be understood that the shape of the second socket portion 273 should not be construed as a limitation on the second electrical connector 27 provided in this embodiment. The second socket portion 273 is used to fix the cable, pressing one end of the cable in place, thereby connecting the second electrical connector 27 to the battery module 220.

[0080] Optionally, the second through hole 2721 can be, but is not limited to, a circular, square or other irregularly shaped through hole. In the schematic diagram of the embodiment of this application, the second through hole 2721 is a circular through hole as an example. It can be understood that the shape of the second through hole 2721 should not be a limitation on the second electrical connector 27 provided in this embodiment.

[0081] Understandably, when the second input / output interface 212 is connected to the battery module 220 via a cable, the second fastener 26 passes sequentially through the second fastener 26, the second connecting part 272, and the converter module from the side of the converter module 20 facing the opening 31, so as to assemble the second fastener 26, the second connecting part 272, and the converter module 20 into one unit; the cable passes through the second sleeve hole 2731, and the battery module 220 is connected to the power control device 100 via the cable.

[0082] In this embodiment, the second electrical connector 27 includes a second connecting portion 272 and a second sleeve portion 273. The second connecting portion 272 has a second through hole 2721. By cooperating with the second fastener 26, the second electrical connector 27 can be stably fixed to the converter module 20. In addition, the second sleeve portion 273 has a second sleeve hole 2731, which is used to pass through a cable, so that the battery module 220 can be connected to the power control device 100 through the wire harness.

[0083] Please see Figure 7 and Figure 8 In some embodiments, the converter module 20 further includes a connector 28 electrically connected to the fourth input / output interface 222, the connector 28 passing through the side wall of the housing 10 and protruding from the outside of the housing 10.

[0084] Explained, the connector 28 of the converter module 20 passes through the housing 10 from the accommodating cavity 11 and extends outside the housing 10. The position of the connector 28 on the side wall of the housing 10 in the figure is only an illustrative position and should not be construed as a limitation on the placement of the connector 28.

[0085] In this embodiment, the connector 28 is electrically connected to the fourth input / output interface 222. The fourth input / output interface 222 is the low-voltage DC output terminal of the DC / DC converter, used to output the low-voltage DC power required by low-voltage electrical appliances. The connector 28 is used to connect to low-voltage electrical appliances or energy storage devices to supply power to them. In other words, the DC / DC converter is used to convert the DC power output from the high-voltage battery into the DC power required by the low-voltage electronic system. The connection interface of the DC / DC converter extends outside the housing 10.

[0086] In this embodiment, the plug interface 28 is electrically connected to the fourth input / output interface 222. The plug interface 28 passes through the side wall of the enclosure 10 and protrudes from the outside of the enclosure 10. This arrangement of the plug interface 28 on the side wall of the enclosure 10 creates an isolation between the high-voltage components and the low-voltage components, ensuring the safe, stable and reliable operation of the electrical system.

[0087] Please see Figure 9 and Figure 10In some embodiments, the AC / DC conversion module 21 further includes a first filter 213, a conversion unit 214, and a second filter 215 connected in series. The first filter 213 is electrically connected to the first input / output interface 211 and is used to filter the AC / DC signals entering and exiting the conversion unit 214. The conversion unit 214 is used to convert AC signals and DC signals. The second filter 215 is electrically connected to the second input / output interface 212 and is used to filter the AC / DC signals entering and exiting the conversion unit 214.

[0088] It should be noted that the first filter 213 can be an AC input / output filter device used to filter out harmonics in AC power.

[0089] It should be noted that the conversion unit 214 can be an AC / DC conversion device, that is, a device that can convert AC input current into DC output current so that the power control device 100 can charge the battery module 220.

[0090] It should be noted that the second filter 215 can be a DC input / output filter device used to filter out harmonics in DC power.

[0091] It should be noted that when an AC signal is connected to the first input / output interface 211, the harmonics in the AC power are first filtered out by the first filter 213, then the AC signal is converted into a DC signal by the conversion unit 214, then the DC signal is filtered out by the second filter 215, and finally the DC signal is output through the second input / output interface 212.

[0092] In this embodiment, by setting the first filter 213, harmonics in the AC power can be filtered out, reducing harmonic interference; by setting the second filter 215, harmonics in the DC power can be filtered out, reducing harmonic interference; and by setting the conversion unit 214, the AC input current can be converted into DC output current, so that the power control device 100 can charge the battery module 220.

[0093] Please see Figure 11 In some embodiments, the converter module 20 further includes a control terminal 29, which is electrically connected to the first input / output interface 211 and the second input / output interface 212 respectively, for controlling the input and output of the AC / DC conversion module 21.

[0094] Optionally, the control terminal 29 is located on the side of the converter module 20 away from the cover 30. The control terminal 29 is electrically connected to the converter module 20. The control terminal 29 is located inside the housing 10, which is beneficial to the miniaturization design of the power control device 100. In addition, it can also avoid collisions with foreign objects and extend the life of the control terminal 29.

[0095] Optionally, the control terminal 29 is located between the first electrical connector 23 and the second electrical connector 27 and is spaced apart from the first electrical connector 23 and the second electrical connector 27 respectively.

[0096] Optionally, the first filter 213, the conversion unit 214 and the second filter 215 are connected in series and then connected in parallel with the control terminal 29.

[0097] Understandably, the control terminal 29 is spaced apart from the first electrical connector 23 and the second electrical connector 27 and has a certain distance between them, so as to prevent the AC input current conversion or DC output current from directly acting on the control terminal 29, thereby causing a short circuit, and to prevent the control terminal 29 from being subjected to electromagnetic interference, thereby enhancing the anti-interference capability of the control terminal 29 and ensuring the safe operation of the control terminal 29.

[0098] Optionally, the control terminal 29 is a low-voltage control section, which typically processes low-voltage signals used to control and manage the entire charging process.

[0099] Specifically, the control terminal 29 is connected to the first input / output interface 211, receives signals from the AC input port, and processes the signals to generate corresponding control commands. The control terminal 29 is also connected to the second input / output interface 212, monitors the parameters of the second input / output interface 212, and adjusts the output parameters as needed to ensure the safety and stability of the charging process.

[0100] In this embodiment, by setting the control terminal 29, the input and output of the AC / DC conversion module 21 can be controlled by receiving the signal from the first input / output interface 211. In addition, by placing the control terminal 29 inside the housing 10, the use of connectors is reduced, which not only reduces production costs but also facilitates the miniaturization design of the power control device 100.

[0101] Please see Figure 9 and Figure 12 In some embodiments, the power control device 100 further includes an isolation plate 40 located within the receiving cavity. The AC / DC conversion module 21 and the transformer module 22 are respectively disposed on opposite sides of the isolation plate 40, with the AC / DC conversion module 21 being disposed closer to the cover 30 than the transformer module 22.

[0102] Understandably, the cover 30, the control terminal 29, and the isolation plate 40 are stacked in sequence.

[0103] Understandably, the AC / DC conversion module 21 is located between the isolation plate 40 and the cover 30, and the transformer module 22 is located on the side of the isolation plate 40 away from the cover 30.

[0104] Optionally, the isolation plate 40 can be, but is not limited to, a plane, a near-plane, other irregular surfaces, or a connection of other irregular surfaces. In the schematic diagram of this embodiment, the isolation plate 40 is illustrated as an example of an irregular surface connection. It should be understood that the shape of the isolation plate 40 should not be construed as a limitation on the isolation plate 40 provided in this embodiment. The isolation plate 40 is used to isolate the AC / DC conversion module 21 from the transformer module 22 to prevent electromagnetic interference.

[0105] Specifically, the isolation plate 40 includes a first isolation portion 41, a second isolation portion 42, and a third isolation portion 43, which are disposed on the bottom wall and sequentially bent and connected. The first isolation portion 41 and the third isolation portion 43 are bent in opposite directions relative to the second isolation portion 42. The first isolation portion 41 is disposed between the AC / DC conversion module 21 and the transformer module 22 to isolate the AC / DC conversion module 21 and the transformer module 22. The second isolation portion 42 is bent and connected to the first isolation portion 41, and the bending angle between the second isolation portion 42 and the first isolation portion 41 can be 90° or approximately 90°. The third isolation portion 43 is connected to the side of the second isolation portion 42 away from the first isolation portion 41, and the third isolation portion 43 is disposed around the outer periphery of the transformer module 22.

[0106] Optionally, the material of the isolation plate 40 can be, but is not limited to, conductive materials such as metal or alloy.

[0107] In this embodiment, the isolation plate 40 is used to isolate the AC / DC conversion module 21 from the transformer module 22 to prevent electromagnetic interference between the AC / DC conversion module 21 and the transformer module 22; in addition, it can also prevent foreign objects from falling into the transformer module 22 and colliding with it, causing damage.

[0108] Please see Figure 2 , Figures 13 to 15In some embodiments, the housing 10 includes a bent and connected bottom plate 12 and side plates 13. The side plates 13 are arranged around the outer periphery of the bottom plate 12, and the bottom plate 12 and the side plates 13 form the receiving cavity 11. The cover 30 is disposed on the side of the side plate 13 opposite to the bottom plate 12 and connected to the side plate 13. The bottom plate 12 has a cooling channel 121, a first channel opening 122, and a second channel opening 123. The cooling channel 121 is located inside the bottom plate 12, and the first channel opening 122 and the second channel opening 123 are respectively connected to the cooling channel 121. At opposite ends of 21, the first flow channel 122 and the second flow channel 123 respectively penetrate the surface of the bottom plate 12 away from the cover 30. The first flow channel 122 and the second flow channel 123 are used to connect to the external cooling system 14. The housing 10 also includes a first sealing ring 15 and a second sealing ring 16. The first sealing ring 15 is disposed at the first flow channel 122 and protrudes from the surface of the bottom plate 12 away from the cover 30. The second sealing ring 16 is disposed at the second flow channel 123 and protrudes from the surface of the bottom plate 12 away from the cover 30.

[0109] Explained, the base plate 12 and the cover 30 are disposed opposite each other, and the side plate 13 is disposed between the base plate 12 and the cover 30 and connects the base plate 12 and the cover 30. The side plate 13 and the base plate 12 can be integrally formed, or they can be connected together in a detachable or non-detachable manner. In this embodiment, the base plate 12 and the side plate 13 are integrally formed, and the cover 30 and the side plate 13 are detachably connected. The base plate 12, the side plate 13, and the cover 30 form an accommodating cavity 11 for accommodating the converter module 20.

[0110] Explained, the base plate 12 has a cooling channel 121, a first channel opening 122, and a second channel opening 123. The cooling channel 121 is located inside the base plate 12 and is used for the flow of coolant. When the cooling channel 121 is connected to coolant, coolant can flow in from the first channel opening 122, flow through the cooling channel 121, and flow out through the second channel opening 123, thereby meeting the heat dissipation requirements of the power control device 100. The cooling channel 121 is used to dissipate heat from the various electronic components located inside the housing 10. The heat dissipation channel can be filled with a heat dissipation fluid. The heat dissipation fluid can be water, oil, etc. Understandably, when the electronic components located inside the housing 10 are positioned close to or against the cooling channel 121, the heat on the electronic components can be transferred to the cooling channel 121 and dissipated to the outside of the housing 10 through the cooling channel 121.

[0111] Explained, the first sealing ring 15 and the second sealing ring 16 are partially embedded in the base plate 12 and partially protrude from the side of the base plate 12 away from the cover 30.

[0112] When the first flow channel 122 and the second flow channel 123 are connected to the external cooling system 14, the first sealing ring 15 and the second sealing ring 16 abut against the external cooling system 14. The first flow channel 122 is connected to the outlet of the external cooling system 14, and the second flow channel 123 is connected to the inlet of the external cooling system 14, thereby enabling the cooling system of the power control device 100 to be connected to the external cooling system 14 and share a circulating cooling system.

[0113] Explained, when the power control device 100 is connected to the external cooling system 14, the sealing rings are squeezed and compressed against each other, the sealing rings tightly abut against the external cooling system 14, and a sealed radiator water channel is formed by connecting the cooling water channel through the sealing rings, so that the power control device 100 can share the cooling water channel with the external cooling system 14, thus meeting the heat dissipation needs of the power control device 100.

[0114] In this embodiment, the external cooling system 14 is connected through the first flow channel 122 and the second flow channel 123, achieving heat dissipation for the converter module 20 without the need for pipes. Simultaneously, the power control device 100 can connect to and share the cooling system with the external cooling system 14, facilitating the assembly of the power control device 100 with other functional components. Furthermore, the cooling system of the power control device 100 is connected to the external cooling system 14 via a first sealing ring 15 and a second sealing ring 16. Since the sealing rings can be compressed, the cooling channel 121 of the power control device 100 and the external cooling system 14 have a good sealing effect. Moreover, this connection method, which does not use pipes, saves assembly space, thereby reducing the size of the power control device 100.

[0115] Please see Figure 13 and Figure 15 In some embodiments, the housing 10 further includes a plurality of mounting portions 17 and a positioning portion 18. The plurality of mounting portions 17 are arranged around the outer periphery of the base plate 12 for mounting the housing 10 to the external cooling system 14 so that the second flow channel 123 communicates with the external cooling system 14. The positioning portion 18 is disposed on the side of the base plate 12 away from the cover 30 and is inserted through the external cooling system 14 to position the relative position of the housing 10 and the external cooling system 14.

[0116] Optionally, the number of positioning parts 18 can be one or more. When there are two positioning parts 18, the positioning parts 18 are arranged in parallel, respectively located on opposite sides of the base plate 12, and the positioning parts 18 pass through the external cooling system 14 and are partially located within the external cooling system 14. When there are multiple positioning parts 18, the multiple positioning parts 18 are spaced apart around the side plates 13 of the housing 10. By providing multiple positioning parts 18, the connection between the power control device 100 and the external cooling system 14 can be made more stable and less prone to displacement.

[0117] Optionally, when there are four mounting parts 17, the mounting parts 17 are arranged opposite each other at both ends of the housing 10. When there are multiple mounting parts 17, the multiple mounting parts 17 are arranged around the outer periphery of the floor. By providing multiple mounting parts 17, the connection between the power control device 100 and the external cooling system 14 can be made more secure, thereby better preventing water leakage from the power control.

[0118] In this embodiment, the mounting part 17 and the positioning part 18 can make the connection between the housing 10 and the external cooling system 14 more secure, and at the same time make the installation of the power control device 100 and the external cooling system 14 more convenient.

[0119] Please see Figure 16 This application provides a power supply system 1000, which includes a battery module 220 and a power control device 100. The power control device 100 is electrically connected to the battery module 220 and is used to control the charging and discharging of the battery module 220.

[0120] In the power supply system 1000 provided in this application, the power control device 100 can be used as a standard miniaturized module that can be easily installed and dissipated, and is convenient to install and connect with the battery module 220.

[0121] Please see Figure 17 This application provides a vehicle 200, which includes a vehicle body 210; a battery module 220; and a power control device 100 as described in this application. The power control device 100 is electrically connected to the battery module 220 and is used to control the charging and discharging of the battery module 220.

[0122] The vehicle 200 in this application embodiment can be, but is not limited to, at least one of automobiles, cars, trucks, vans, buses, freight vehicles, tractor-trailers, special transport vehicles, and special vehicles.

[0123] It should be noted that the vehicle 200 includes the vehicle body 210, the battery module 220, and the power control device 100. Figure 17The positions of the battery module 220 and the power control device 100 in the vehicle 200 are merely illustrative and should not be construed as limiting the placement of the battery module 220 and the power control device 100. The power control device 100 is located inside the housing of the battery module 220.

[0124] Optionally, the battery module 220 is a secondary battery, which may include one or more of the following: lead-acid battery, nickel-cadmium battery, nickel-metal hydride battery, lithium-ion battery, lithium metal battery, etc.

[0125] The vehicle 200 in this embodiment includes a vehicle body 210, a battery module 220, and a power control device 100. The power control device 100 is electrically connected to the battery module 220 and is used to control the charging and discharging of the battery module 220. The power control device 100 integrates a DC-DC converter module and a transformer module 22, simultaneously realizing the charging and power supply of the vehicle 200. This reduces the use of connectors and wiring harnesses, thereby reducing the space occupied by the power control device 100 in the vehicle 200, and thus reducing the overall vehicle weight and manufacturing cost. The power control device 100 includes a housing 10 with an open cavity 11 at one end; a converter module 20 including an AC / DC conversion module 21, a transformer module 22, and a first electrical connector 23; the AC / DC conversion module 21 having a first input / output interface 211 and a second input / output interface 212; the transformer module 22 having a third input / output interface 221 and a fourth input / output interface 222; the first electrical connector 23 is electrically connected to the first input / output interface 211 for connecting to an external power source; the second input / output interface 212 is electrically connected to the third input / output interface 221; and a cover 30 disposed at the opening of the housing 10 for closing the cavity 11, the cover 30 having a window 31 corresponding to the first electrical connector 23. The power control device 100 integrates the AC / DC conversion module 21 and the transformer module 22. Both the AC / DC conversion module 21 and the transformer module 22 are housed within the accommodating cavity 11, facilitating full utilization of the cavity's space and achieving integrated design. When the AC / DC conversion module 21 and the transformer module 22 are assembled into the battery system, compared to a separate enclosure, the power control device 100 provided in this application saves space occupied by the battery system, improves space utilization, and promotes miniaturization of the battery system. Furthermore, the multi-functional integrated power control device 100 connects directly to corresponding functional components via wiring harnesses, reducing the connection of input, output, and control connectors, thereby lowering the overall vehicle weight and manufacturing cost. Moreover, the power control device 100 can serve as a standard miniaturized module that is easy to install and dissipate heat, meeting the needs of various new energy vehicles for convenient and multi-functional electric drive assemblies or power battery CTC installation and connection.

[0126] In this application, the terms "embodiment" and "implementation" mean that a specific feature, structure, or characteristic described in connection with an embodiment can be included in at least one embodiment of this application. The appearance of these phrases in various locations throughout the specification does not necessarily refer to the same embodiment, nor are they independent or alternative embodiments mutually exclusive with other embodiments. Those skilled in the art will understand, explicitly and implicitly, that the embodiments described in this application can be combined with other embodiments. Furthermore, it should be understood that the features, structures, or characteristics described in the various embodiments of this application can be arbitrarily combined to form yet another embodiment that does not depart from the spirit and scope of the technical solution of this application, provided there is no contradiction between them.

[0127] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application and are not intended to limit it. Although this application has been described in detail with reference to the above preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions to the technical solutions of this application should not depart from the spirit and scope of the technical solutions of this application.

Claims

1. A power control device, characterized in that, include: A housing having an accommodating cavity open at one end; A converter module, comprising an AC / DC conversion module, a transformer module, and a first electrical connector; The AC / DC conversion module has a first input / output interface and a second input / output interface; the transformer module has a third input / output interface and a fourth input / output interface; the first electrical connector is electrically connected to the first input / output interface for connecting to an external power source; the second input / output interface is electrically connected to the third input / output interface. as well as A cover is disposed at the opening of the housing to close the accommodating cavity. The cover has a window, which is provided corresponding to the first electrical connector.

2. The power control device according to claim 1, characterized in that, The converter module further includes a circuit board and a first fastener. The circuit board is used to mount the converter module. The first electrical connector includes a first plug-in portion, a first connecting portion, and a first socket portion that are bent and connected in sequence. The first plug-in portion and the first socket portion are bent toward the same side relative to the first connecting portion. The first plug-in portion is inserted into the circuit board. The first connecting portion has a first through hole for the first fastener to pass through, so as to electrically connect the first electrical connector to the first input / output interface. The first socket has a first sleeve hole for threading a cable to connect to an external power source.

3. The power control device according to claim 2, characterized in that, The converter module further includes a second fastener and a second electrical connector. The second electrical connector includes a second plug-in portion, a second connecting portion, and a second socket portion that are bent and connected in sequence. The second plug-in portion and the second socket portion are bent toward the same side relative to the second connecting portion. The second plug-in portion is plugged into the circuit board. The second connecting portion has a second through hole for inserting the second fastener to electrically connect the second electrical connector to the second input / output interface. The second socket has a second sleeve hole for threading a cable to electrically connect to the third input / output interface.

4. The power control device according to claim 1, characterized in that, The converter module also includes a connector that is electrically connected to the fourth input / output interface. The connector passes through the side wall of the housing and protrudes from the outside of the housing.

5. The power control device according to claim 1, characterized in that, The AC / DC conversion module further includes a first filter, a conversion unit, and a second filter connected in series. The first filter is electrically connected to the first input / output interface and is used to filter the AC / DC signals entering and exiting the conversion unit. The conversion unit is used to convert AC signals and DC signals. The second filter is electrically connected to the second input / output interface and is used to filter the AC / DC signals entering and exiting the conversion unit.

6. The power control device according to claim 1, characterized in that, The converter module also includes control terminals, which are electrically connected to the first input / output interface and the second input / output interface respectively, for controlling the input and output of the AC / DC conversion module.

7. The power control device according to claim 1, characterized in that, The power control device also includes an isolation plate located within the accommodating cavity. The AC / DC conversion module and the transformer module are respectively disposed on opposite sides of the isolation plate, with the AC / DC conversion module being disposed closer to the cover than the transformer module.

8. The power control device according to claim 1, characterized in that, The housing includes a bent and connected bottom plate and side plates. The side plates are arranged around the outer periphery of the bottom plate, and the bottom plate and the side plates form the receiving cavity. The cover is disposed on the side of the side plate away from the bottom plate and connected to the side plate. The bottom plate has a cooling channel, a first channel opening, and a second channel opening. The cooling channel is located inside the bottom plate. The first channel opening and the second channel opening are respectively connected to opposite ends of the cooling channel. The first channel opening and the second channel opening respectively penetrate the surface of the bottom plate away from the cover and are used to connect to an external cooling system. The housing also includes a first sealing ring and a second sealing ring. The first sealing ring is disposed at the first channel opening and protrudes from the surface of the bottom plate away from the cover, and the second sealing ring is disposed at the second channel opening and protrudes from the surface of the bottom plate away from the cover.

9. The power control device according to claim 8, characterized in that, The enclosure also includes multiple mounting parts and positioning parts. The multiple mounting parts are arranged around the outer periphery of the base plate and are used to install the enclosure onto an external cooling system so that the first flow channel and the second flow channel are connected to the external cooling system. The positioning part is located on the side of the base plate away from the cover and is used to pass through the external cooling system to position the relative position of the enclosure and the external cooling system.

10. A power supply system, characterized in that, The power supply system includes: Battery modules, and; The power control device according to any one of claims 1-9, wherein the power control device is electrically connected to the battery module and is used to control the charging and discharging of the battery module.

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