Integrated BDU and battery pack

Abstract

The utility model discloses an integrated BDU, which comprises an upper shell and a lower shell, the upper shell and the lower shell are clamped to form a BDU cavity for accommodating high-voltage electric devices, a plurality of insulating fixing seats for mounting the high-voltage electric devices are arranged in the lower shell, and insulating partition plates for separating the high-voltage electric devices are arranged in the lower shell. Insulating ribs are arranged at the output pole positions of the high-voltage electric devices in the lower shell. A high-voltage connector and a low-voltage connector are respectively fixed at the side part and the lower part of the lower shell through a mounting part and a mounting hole, a leading-out wire harness of the high-voltage connector is arranged in the BDU cavity, a leading-out wire harness of the low-voltage connector is arranged on the lower surface of the lower shell, and a wire passing groove for the low-voltage wire harness to pass through is formed in the lower shell. According to the utility model, the cavity space of the BDU can be fully utilized, the integration level of the BDU is improved, and the space utilization rate of the BDU in the battery pack is improved.

Description

Technical Field

[0001] This utility model belongs to the field of battery technology, specifically relating to an integrated BDU and battery pack. Background Technology

[0002] The Battery Energy Distribution Unit (BDU), also known as the Battery Disconnect Unit, is a dedicated power distribution box for the power batteries of electric vehicles. It provides functions such as pre-charging, supercharging, discharge control, circuit overload and short circuit protection, high voltage sampling, and low voltage control for the high voltage system of new energy vehicles, protecting and monitoring the operation of the high voltage system.

[0003] With the development of technology, the integration of battery pack integration units (BDUs) into battery packs is becoming increasingly common. BDUs contain high and low voltage connectors, fuses, relays, and high-voltage electrical components such as copper busbars for high-voltage connections. In order to meet the requirements of electrical clearance and creepage distance, a certain distance needs to be set between each component, resulting in low integration level of BDUs and large space occupation, which affects the layout within the battery pack. Utility Model Content

[0004] The purpose of this invention is to provide an integrated BDU and battery pack that can make full use of the BDU cavity space, improve the integration of the BDU, and enhance the space utilization rate of the BDU within the battery pack.

[0005] To achieve the above objectives, the present invention provides an integrated BDU, comprising an upper housing and a lower housing, which are snapped together to form a BDU cavity for accommodating high-voltage electrical components. The lower housing contains several insulating mounting bases for installing high-voltage electrical components, insulating partitions that separate each high-voltage electrical component, and insulating ribs located at the output pole positions of the high-voltage electrical components within the lower housing.

[0006] The side and bottom of the lower housing are fixed with a high-voltage connector and a low-voltage connector respectively through a mounting part and a mounting hole. The high-voltage connector lead wire harness is arranged in the BDU cavity, and the low-voltage connector lead wire harness is arranged on the lower surface of the lower housing. The lower housing is provided with a wire passage groove for the low-voltage wire harness to pass through.

[0007] As a further embodiment of this utility model: the upper housing includes an upper housing body and a detachable upper cover 1 for MSD maintenance, a detachable upper cover 2 for relay maintenance, a detachable upper cover 3 for battery input stage assembly, and a detachable upper cover 4 that are snapped together with the upper housing body.

[0008] As a further embodiment of this utility model: the upper shell body is manufactured by integral molding, and several heat dissipation and weight reduction holes are provided on the upper shell body.

[0009] As a further embodiment of this utility model: the lower shell, the insulating fixing seat, the insulating partition, and the insulating rib are integrally formed.

[0010] As a further embodiment of this utility model, a wire-fixing ring is provided on the lower housing corresponding to the wire groove.

[0011] To achieve the above objectives, this utility model also provides a battery pack, including the aforementioned integrated BDU, with the lower housing installed inside the battery pack.

[0012] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0013] 1. By separating the high-voltage electrical components in the BDU cavity with insulating partitions, the arrangement of the high-voltage electrical components can be made more compact, and more high-voltage electrical components can be arranged in the same space.

[0014] 2. Insulating ribs are installed at the output poles of multiple high-voltage electrical components in the BDU cavity to reduce electrical clearance and creepage distance;

[0015] 3. By setting several insulating mounting bases inside the lower housing, high-voltage electrical components can be mounted on the insulating mounting bases, making full use of the space in the height of the BDU. The lower space can be used more to distribute high-voltage wire harnesses.

[0016] 4. Make reasonable use of the space under the lower housing to arrange low-voltage wiring harnesses, so as to separate high-voltage wiring harnesses from low-voltage wiring harnesses. This can effectively reduce signal interference problems and make the overall structure more compact. Attached Figure Description

[0017] Figure 1 This is a structural schematic diagram of the integrated BDU of this utility model.

[0018] Figure 2 This is a schematic diagram of the lower shell structure of the integrated BDU of this utility model.

[0019] Figure 3 This is a schematic diagram of the bottom view structure of the integrated BDU of this utility model.

[0020] Figure 4 This is a schematic diagram of the internal component distribution structure of the integrated BDU of this utility model.

[0021] Figure 5 This is a schematic diagram of the integrated BDU of this utility model applied in a battery pack.

[0022] In the diagram: 1. Upper housing, 2. Low-voltage connector, 3. High-voltage connector, 4. Low-voltage wiring harness, 5. Lower housing, 6. Insulating partition, 7. Insulating rib, 8. Wire ring, 9. Insulating mounting base, 10. Heating positive relay, 11. Heating fuse, 12. Pre-charge resistor, 13. Charging negative relay, 14. Charging positive relay, 15. Discharging positive relay, 16. Discharging negative relay, 17. Current sensor, 18. Heating negative relay, 19. Fuse, 20. Pre-charge relay;

[0023] 1-1. Removable top cover one; 1-2. Removable top cover two; 1-3. Removable top cover three; 1-4. Removable top cover four. Detailed Implementation

[0024] The present invention will be further described below with reference to the accompanying drawings.

[0025] like Figures 1 to 3 As shown, the integrated BDU includes an upper housing 1 and a lower housing 5. The upper housing 1 and the lower housing 5 are snapped together to form a BDU cavity for accommodating high-voltage electrical components. The lower housing 5 is provided with several insulating mounting bases 9 for installing high-voltage electrical components. By mounting the high-voltage electrical components on the insulating mounting bases 9, the space in the height of the BDU is fully utilized, and the lower space can be used more to distribute high-voltage wiring harnesses. The lower housing 5 is provided with insulating partitions 6 to separate each high-voltage electrical component, which can make the arrangement design between the high-voltage electrical components more compact, and thus more high-voltage electrical components can be arranged in the same space. The lower housing 5 is provided with insulating ribs 7 at the output pole positions of the high-voltage electrical components, which can reduce electrical clearance and creepage distance.

[0026] The high-voltage connector 3 and the low-voltage connector 2 are fixed to the side and bottom of the lower housing 5 through the mounting part and mounting hole, respectively. The high-voltage connector 3 leads out the wire harness and is arranged in the BDU cavity, while the low-voltage connector 2 leads out the wire harness and is arranged on the lower surface of the lower housing 5. The lower housing 5 is provided with a wire groove for the low-voltage wire harness 4 to pass through, making full use of the space below the lower housing 5 to arrange the low-voltage wire harness 4, so that the low-voltage wire harness 4 and the high-voltage wire harness are separated, effectively reducing signal interference problems, and at the same time, making the overall structure more compact.

[0027] To facilitate maintenance, the upper housing 1 further includes an upper housing body and a removable upper cover 1-1 for MSD maintenance, a removable upper cover 1-2 for relay maintenance, a removable upper cover 1-3 for battery input stage assembly, and a removable upper cover 1-4.

[0028] Furthermore, the upper shell is manufactured using a one-piece molding method, and several heat dissipation and weight reduction holes are formed on the upper shell. These heat dissipation and weight reduction holes can be used for heat dissipation and to reduce the overall weight of the BDU.

[0029] Furthermore, the lower housing 5, insulating mounting base 9, insulating partition 6, and insulating rib 7 are integrally formed. The heights of the insulating partition 6, insulating rib 7, and insulating mounting base 9 can be flexibly set according to the placement and height of the high-voltage electrical components, effectively isolating adjacent high-voltage electrical components.

[0030] The cable tray allows the low-voltage cable harness 4, located below the lower housing 5, to be introduced into the BDU cavity. To prevent the low-voltage cable harness 4 from falling downwards, a cable retaining ring 8 is further provided on the lower housing 5 corresponding to the cable tray. This effectively restricts the low-voltage cable harness 4 and maintains its arrangement.

[0031] like Figure 5 As shown, a battery pack includes the aforementioned integrated BDU, and a lower housing 5 is installed inside the battery pack.

[0032] In specific implementation of this utility model, such as Figure 4 As shown, a current sensor 17 is connected and arranged above the high-voltage connector 3. A heating fuse 11 and a pre-charge resistor 12 are connected and arranged on the opposite side of the current sensor 17. On the other two sides of the BDU cavity, a charging negative relay 13, a charging positive relay 14, a discharging positive relay 15, and a discharging negative relay 16 are connected and arranged in sequence on one side, and a heating positive relay 10, a pre-charge relay 20, a fuse 19, and a heating negative relay 18 are connected and arranged in sequence on the other side.

[0033] Copper busbar 1: One end is connected to the positive terminal of the external heating wire harness, and the other end is connected to the heating positive terminal relay 10;

[0034] Copper busbar 2: One end is connected to the fuse 19 terminal, and the other end is connected to the removable top cover 1-2 area;

[0035] Copper busbar three: One end is connected to the charging positive relay 14 and the discharging positive relay 15, and the other end is connected to the detachable top cover area 1-2.

[0036] Copper busbar 4: One end is connected to the charging negative relay 13 and the discharging negative relay 16, and the other end is connected to the current sensor 17.

[0037] Copper busbar 5: One end is connected to terminal 18 of the heating negative relay, and the other end is connected to area 1-1 of the removable top cover;

[0038] Copper busbar 6: One end is connected to the heating positive relay 10, and the other end is connected to the heating fuse 11;

[0039] Copper busbar 7: One end is connected to the detachable top cover 3 area 1-3 via the insulating fixing seat 9, and the other end is connected to the current sensor 17;

[0040] Copper busbar 8: One end is connected to the negative terminal of the external heating harness, and the other end is connected to the heating negative terminal relay 18.

[0041] Using bent copper busbars as the busbars reduces the space occupied by the busbars and makes the electrical components more compact.

[0042] Figure 4 In the circuit, the right side of fuse 19 is used to connect to the positive input of the battery, and the left side is connected to the insulating mounting base 9 via copper busbar 2; copper busbar 3 connects the discharge positive relay 15 and the charging positive relay 14; an MSD or smart fuse can be placed between copper busbar 2 and copper busbar 3 to cut off the power supply of the entire positive circuit. The entire positive circuit includes: copper busbar 2, copper busbar 3, copper busbar 6, fuse 19, charging positive relay 14, discharge positive relay 15, pre-charge relay 20, and pre-charge resistor 12; the pre-charge circuit connects the pre-charge resistor 12 and the pre-charge relay 20 in parallel to the positive circuit through an internal wiring harness to achieve the pre-charge function; heating is achieved by bolting the annular terminal of the positive terminal of the external heating wiring harness to copper busbar 1; internally, the heating fuse 11 is bolted to copper busbar 2 to form the heating positive circuit.

[0043] The entire negative circuit includes: copper busbar 7, copper busbar 8, copper busbar 5, copper busbar 4, heating negative relay 18, current sensor 17, discharging negative relay 16, and charging negative relay 13. Heating is achieved by connecting the ring terminal of the external heating harness negative terminal and copper busbar 8 with bolts. Internally, heating negative relay 18 is connected to the crimping bolt position of copper busbar 4 to form the heating negative circuit.

Claims

1. An integrated BDU, comprising an upper housing (1) and a lower housing (5), characterized in that, The upper shell (1) and the lower shell (5) are snapped together to form a BDU cavity for accommodating high-voltage electrical devices. The lower shell (5) is provided with several insulating fixing seats (9) for installing high-voltage electrical devices. The lower shell (5) is provided with insulating partitions (6) that separate each high-voltage electrical device. The lower shell (5) is provided with insulating ribs (7) at the output pole positions of the high-voltage electrical devices. The lower housing (5) has a high-voltage connector (3) and a low-voltage connector (2) fixed on its side and bottom through mounting parts and mounting holes, respectively. The high-voltage connector (3) leads out a wire harness and is arranged in the BDU cavity. The low-voltage connector (2) leads out a wire harness and is arranged on the lower surface of the lower housing (5). The lower housing (5) is provided with a wire groove for the low-voltage wire harness (4) to pass through.

2. The integrated BDU according to claim 1, characterized in that, The upper housing (1) includes an upper housing body and a removable upper cover one (1-1) that snaps into the upper housing body for MSD maintenance, a removable upper cover two (1-2) for relay maintenance, a removable upper cover three (1-3) for battery input stage assembly, and a removable upper cover four (1-4).

3. The integrated BDU according to claim 2, characterized in that, The upper shell is manufactured using a one-piece molding method, and several heat dissipation and weight reduction holes are provided on the upper shell.

4. The integrated BDU of claim 1, wherein, The lower housing (5), insulating fixing seat (9), insulating partition (6), and insulating rib (7) are integrally formed.

5. The integrated BDU according to claim 1, characterized in that, A wire-fixing ring (8) is provided on the lower housing (5) corresponding to the wire groove.

6. A battery pack, characterized in that, Includes the integrated BDU as described in any one of claims 1-5, and the lower housing (5) is installed inside the battery pack.

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