Multi-channel intelligent power distribution box

Abstract

The utility model provides a multi-channel intelligent power distribution box. Comprising a box body, a plurality of contactors and pre-charging resistors are arranged in the box body, nine high-voltage load channels and twelve low-voltage load channels are formed between the contactors and the pre-charging resistors through a plurality of over-current copper bars, and the intersections of the over-current copper bars are isolated and supported through insulating supporting pieces; a plurality of load interfaces are arranged outside the box body and are respectively connected with a plurality of contactors through over-current copper bars; the contactor is further connected with a control module, a current detection assembly and a voltage detection assembly are arranged in the control module, and a plurality of signal interfaces are arranged outside the box body and connected with the control module. Power supply switch control contactors of multiple devices are integrated in the control box, the problem that a user needs to pay attention to the layout of the control contactors on a vehicle and consider the waterproof and dustproof functions of a high-voltage system is solved, and each power supply channel has the functions of current detection, voltage detection and adhesion detection.

Description

Technical Field

[0001] This utility model relates to a multi-channel intelligent power distribution box and its working method. Background Technology

[0002] Over the past two decades, with increasing environmental awareness and adjustments to the energy structure, electric vehicles have gradually become an important development direction for the automotive industry. As a core component of the electric vehicle's power system, the high-voltage power distribution module undertakes the crucial tasks of power distribution and management, leading to increased research and development demands. Technological advancements mean that vehicle users are no longer solely focused on the vehicle's driving capabilities. According to reliable statistics, current users consider additional requirements such as vehicle safety and reliability, and intelligent systems when choosing new energy vehicles. This implies that the design of vehicle electrical and driving systems will become more complex, yet the spatial structure will be simpler. The high-voltage power distribution box, with its integration, excellent sealing, and stable operation, effectively solves the challenges in vehicle power systems.

[0003] High-voltage switch boxes are now widely used in energy storage equipment, new energy vehicle power systems, and other fields. Currently, most high-voltage switch boxes used in new energy electric vehicles operate at voltages between 230 and 450V DC. Functionally, these products typically include basic features such as pre-charging and fuse protection, and generally use contactors without auxiliary contacts for channel control. To improve driving range and space utilization, the industry has placed higher demands on high-voltage switch boxes. Strong load-bearing capacity, low cost, ease of use, timely protection response, and high safety performance have become the new directions for the development of the high-voltage switch box industry.

[0004] To improve the system's range and the load capacity of other equipment, electric vehicles are increasingly adopting high-voltage systems ranging from 300V to 800V. Under high-current, high-voltage conditions, the safety requirements for human-machine interfaces are more stringent. The load-carrying power requirements are higher, monitoring needs need to be upgraded, protection measures need to be increased, and intelligent decision-making design is required. The product structure must also be easy to install and safe and reliable. Currently, most high-voltage distribution boxes on the market can operate stably in terms of performance, but their decision-making in special operating conditions is not entirely reliable for users. Especially with the current trend of increasing vehicle range, expanding battery energy storage capacity, and adding intelligent systems, most high-voltage distribution boxes on the market only consider unidirectional reception of vehicle VCU management commands. The products have limited measures for judging the status of channels, and the detection accuracy of current and voltage is typically only 5%~3%. At the same time, with the increase in load, the number of internal power supply channels also increases, and control errors and interference may occur in the system circuit. Therefore, products need to have good intelligent decision-making performance and anti-interference measures to ensure normal product operation and user safety. For example, CN221861987U discloses a high-voltage distribution box that connects to a contactor via a copper busbar. The conductive element is housed within the internal casing, replacing the exposed end of the copper busbar which directly contacts and connects to the external connector. This reduces the risk of arcing and short circuits caused by accidental contact with metal objects or improper operation, thereby preventing safety accidents. However, it does not provide a waterproof interface on the contactor housing. Utility Model Content

[0005] To solve the above-mentioned technical problems, this utility model provides a multi-channel intelligent power distribution box.

[0006] This utility model is achieved through the following technical solution.

[0007] The purpose of this utility model is to solve the technical deficiencies of existing high-voltage distribution box safety protection measures. In similar products, it can overcome the problems of untimely response and cumbersome maintenance caused by existing control and protection methods when working under rated 600V DC, 10~600A load, which may damage the vehicle's power system due to overcurrent and overvoltage. This utility model provides two protection measures: fast response recoverable protection decision and slow response non-recoverable protection decision. The fast response recoverable protection decision can protect according to the product's working conditions.

[0008] This product addresses the issues of insufficient detection accuracy and lack of information regarding the operating status of existing high-voltage distribution boxes. It incorporates built-in current, voltage, and temperature monitoring and recording functions to provide users with real-time data for easy analysis of operating conditions.

[0009] This paper addresses the problem that existing products lack auxiliary contacts, making it impossible to monitor the current status of channels before power-on and to correctly determine the abnormal linkage of contactors with auxiliary contacts after power-on. It provides a highly reliable design solution that enables combined judgment.

[0010] This utility model provides a multi-channel intelligent power distribution box; it includes a housing, inside which are arranged several contactors and pre-charging resistors. The contactors and pre-charging resistors are connected by several current-carrying copper busbars to form nine high-voltage load channels and twelve low-voltage load channels. The intersections of the several current-carrying copper busbars are isolated and supported by insulating support members. Outside the housing, there are several load interfaces, which are connected to several contactors respectively through current-carrying copper busbars. The contactors are also connected to a control module, which includes current detection components and voltage detection components. Outside the housing, there are several signal interfaces connected to the control module.

[0011] The signal interface and load interface are located on opposite outer walls of the enclosure, and several mounting ears are evenly installed on the other two opposite outer walls of the enclosure.

[0012] The signal interface and load interface are installed in a waterproof groove machined on the enclosure, and a sealing strip is provided in the waterproof groove.

[0013] It also includes extreme condition handling, which activates the minimum system logic when bus communication fails, maintaining only the power supply channels for the drive motor, braking system and core control unit.

[0014] The operating method of a multi-channel intelligent power distribution box includes the following steps:

[0015] Real-time data acquisition: The system continuously acquires current, voltage, and temperature data from each channel through current detection components, voltage detection components, and temperature detection systems.

[0016] Fault level determination:

[0017] Level 1 fault determination: If the instantaneous current value exceeds 600A or the instantaneous voltage value exceeds 650V DC, the fast response recovery protection module is triggered, dynamically adjusting the protection threshold and continuously reporting the status.

[0018] Level 2 fault determination: If the current continuously exceeds 800A for 100ms or the voltage continuously exceeds 700V DC for 200ms, the slow response non-recoverable protection module is triggered, and the power supply of the corresponding channel is cut off.

[0019] Fault channel isolation and reporting: After disconnecting the fault channel, the fault type and channel number are reported through the dual redundant CAN interface, and the current, voltage, temperature and command signal data at the time of the fault are stored.

[0020] The execution flow of the minimum system logic includes: cutting off all non-safety load channels, maintaining power supply to the core control unit through backup power, and ensuring basic driving functions.

[0021] The switching logic of the dual-redundant CAN interface in the event of communication failure is as follows: after the primary CAN interface fails, it switches to the backup CAN interface after a 50ms delay; if the backup CAN interface still cannot communicate, the "minimum system logic" is triggered.

[0022] During the real-time data acquisition process, the potential difference of at least three low-voltage or high-voltage channels is also collected to determine the linkage status between the main contact and the auxiliary contact. If the feedback voltage of the auxiliary contact deviates from the expected value by more than 5%, it is determined to be an linkage abnormality and triggers a self-test alarm.

[0023] The beneficial effects of this utility model are as follows: It integrates the power supply switch control contactors of multiple devices into a control box, solving the problem that users need to consider both the layout of the control contactors on the vehicle and the waterproofing and dustproofing of the high-voltage system. Each power supply channel has current detection, voltage detection, and adhesion detection functions. When any channel inside the product malfunctions, a corresponding alarm will be triggered. The product makes operating decisions based on the fault level. Normal operating data and data that do not affect the overall system will continue to operate normally and continuously report operating status parameters; for more serious or harmful faults, the fault type and corresponding channel will be continuously reported. Users can quickly locate the fault node, view and replace it in a timely manner, reducing fault repair time. It has an information storage function, saving the current, voltage parameters, and command signals at the time of the fault after it occurs, facilitating fault analysis and location. After correction, it can be eliminated through specific frame commands. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the structure of the device of this utility model;

[0025] Figure 2 Schematic diagram of the multi-channel layout principle of this utility model;

[0026] Figure 3 This is a schematic diagram of the intelligent decision-making protection process of this utility model;

[0027] Figure 4 This is a schematic diagram illustrating the working principle of the control module of this utility model;

[0028] In the diagram: 1-box, 2-signal interface, 3-contactor, 4-pre-charge resistor, 5-insulating support, 6-load interface, 7-mounting ear, 8-control module, 9-overcurrent copper busbar. Detailed Implementation

[0029] The technical solution of this utility model is further described below, but the scope of protection is not limited to what is described.

[0030] A multi-channel intelligent power distribution box includes a housing 1, inside which are a plurality of contactors 3 and pre-charging resistors 4. The contactors 3 and pre-charging resistors 4 are connected by a plurality of current-carrying copper busbars 9 to form nine high-voltage load channels and twelve low-voltage load channels. The intersections of the plurality of current-carrying copper busbars 9 are isolated and supported by insulating support members 5. Outside the housing 1 are a plurality of load interfaces 6, which are connected to the plurality of contactors 3 respectively through the current-carrying copper busbars 9. The contactors 3 are also connected to a control module 8, which contains current detection components and voltage detection components. Outside the housing 1 are a plurality of signal interfaces 2 connected to the control module 8.

[0031] The signal interface 2 and the load interface 6 are located on opposite outer walls of the housing 1, and a number of mounting ears 7 are evenly installed on the other two opposite outer walls of the housing 1.

[0032] The signal interface 2 and load interface 6 are installed in a waterproof groove machined into the enclosure, and a sealing strip is provided inside the waterproof groove. The silicone sealing strip provides IP67 waterproof and dustproof performance, adapting to harsh environments such as humid and dusty conditions.

[0033] Both the bottom and top are equipped with thermally conductive silicone. The thermal silicone layer improves the contact efficiency between the enclosure and the external heat dissipation structure, reduces internal temperature rise, eliminates the need for additional heat dissipation devices, and reduces energy consumption and maintenance costs.

[0034] The operating method of a multi-channel intelligent power distribution box includes the following steps:

[0035] Real-time data acquisition: The system continuously acquires current, voltage, and temperature data from each channel through current detection components, voltage detection components, and temperature detection systems.

[0036] Fault level determination:

[0037] Level 1 fault determination: If the instantaneous current value exceeds 600A or the instantaneous voltage value exceeds 650V DC, the fast response recovery protection module is triggered, dynamically adjusting the protection threshold and continuously reporting the status.

[0038] Level 2 fault determination: If the current continuously exceeds 800A for 100ms or the voltage continuously exceeds 700V DC for 200ms, the slow response non-recoverable protection module is triggered, and the power supply of the corresponding channel is cut off.

[0039] Fault channel isolation and reporting: After disconnecting a fault channel, the fault type and channel number are reported via a dual-redundant CAN interface, and the current, voltage, temperature, and command signal data at the time of the fault are stored. Real-time data acquisition supports high-precision energy management, providing a reliable data foundation for vehicle control; the fault classification and judgment strategy reduces malfunctions and balances system safety and operational continuity; the fault channel isolation and reporting function shortens fault location time and improves maintenance efficiency.

[0040] It also includes extreme condition handling. When bus communication fails, the minimum system logic is activated to maintain power supply to only the drive motor, braking system, and core control unit. The minimum system logic ensures basic driving safety under extreme conditions and prevents complete vehicle failure; non-safe loads are automatically disconnected to reduce the risk of secondary failures.

[0041] The execution flow of the minimum system logic includes: cutting off all non-safety load channels, maintaining power supply to the core control unit through backup power, and ensuring basic driving functions.

[0042] The switching logic of the dual-redundant CAN interface in the event of communication failure is as follows: after the primary CAN interface fails, it switches to the backup CAN interface after a 50ms delay; if the backup CAN interface still cannot communicate, the "minimum system logic" is triggered.

[0043] During the real-time data acquisition process, the potential difference of at least three low-voltage or high-voltage channels is also collected to determine the linkage status between the main contact and the auxiliary contact. If the feedback voltage of the auxiliary contact deviates from the expected value by more than 5%, it is determined to be an linkage abnormality and triggers a self-test alarm.

[0044] The core actuator in the high-voltage distribution box is the high-voltage contactor, which operates at 24VDC. In the electronic and electrical architecture of new energy electric vehicles, the control of the actuator has shifted from hard-wired enabled control to bus enabled control. The design challenges of the bus in the high-voltage distribution box lie in anti-interference design, ensuring effective command execution after bus interference, and defining and executing the minimum safety system after bus interference. To address these issues, we implemented PCB anti-interference circuitry and shielded wiring harnesses during bus design. We also implemented a dual-redundancy design for the bus circuitry to ensure the reliability of bus signals. To address the issue of real-time communication failure due to bus interference, we incorporated minimum execution system logic into the logic control to ensure the safe operation of the minimum system in the event of complete bus interference or disconnection.

Claims

1. A multi-channel intelligent power distribution box, characterized in that: The enclosure includes a housing (1), which contains several contactors (3) and pre-charge resistors (4). The contactors (3) and pre-charge resistors (4) are connected by several overcurrent copper busbars (9) to form nine high-voltage load channels and twelve low-voltage load channels. The intersections of the several overcurrent copper busbars (9) are isolated and supported by insulating support members (5). The enclosure (1) is provided with several load interfaces (6) outside, which are connected to several contactors (3) through the overcurrent copper busbars (9). The contactors (3) are also connected to a control module (8). The control module (8) contains a current detection component and a voltage detection component. The enclosure (1) is provided with several signal interfaces (2) outside, which are connected to the control module (8).

2. The multi-channel intelligent power distribution box as described in claim 1, characterized in that: The signal interface (2) and the load interface (6) are located on opposite outer walls of the enclosure (1), and a number of mounting ears (7) are evenly installed on the other two opposite outer walls of the enclosure (1).

3. The multi-channel intelligent power distribution box as described in claim 1, characterized in that: The signal interface (2) and the load interface (6) are installed in a waterproof groove machined on the housing, and a sealing strip is provided in the waterproof groove.

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