Relay distribution board for new energy automobile

Abstract

The utility model discloses a relay distribution board for a new energy automobile, which comprises a circuit board. The circuit board is provided with a small top-mounted pre-charging relay, a large top-mounted pre-charging relay, an MCU pre-charging relay, a large power distribution pre-charging relay, a driving wiring terminal, a sampling signal terminal, a first wiring nut, a second wiring nut, a third wiring nut, a fourth wiring nut, a first voltage sampling wire terminal and a divider resistor. The small top-mounted pre-charging relay, the large top-mounted pre-charging relay, the MCU pre-charging relay and the large power distribution pre-charging relay are all connected with the circuit board through the first voltage sampling line terminal. The circuit board is simple in circuit, small in size and capable of reducing occupied space of the circuit board due to the fact that a small-package relay is used for pre-charging; the design period is short, the power distribution difference requirements of different vehicle types can be met, rapid batch can be achieved, compact layout can be achieved on a circuit board, the height of the relay is moderate, the relay can be completely matched in a whole vehicle case, and the position of a heat dissipation copper bar cannot be blocked or occupied.

Description

A relay distribution board for new energy vehicles Technical Field

[0001] This utility model relates to the field of new energy vehicle technology, specifically to a relay distribution board for new energy vehicles. Background Technology

[0002] With increasing environmental awareness and advancements in science and technology, new energy vehicles are developing rapidly worldwide. The power distribution scheme consisting of a pre-charge relay and voltage divider resistors is mainly used in battery management systems (BMS) and high-voltage power distribution systems. Its core function is to ensure the safe and efficient operation of the battery pack and to monitor the current in real time.

[0003] Early relays used in new energy vehicles were bulky and heavy, making installation in space-constrained vehicles inconvenient and impacting overall vehicle layout and lightweight design. Furthermore, the mechanical contacts of these relays resulted in slow operation, failing to meet the rapid response requirements of new energy vehicles. Simultaneously, the vibration and wear of the mechanical contacts affected control accuracy and reduced system reliability. In addition, traditional relays had limited functionality, unable to meet the intelligent power distribution management needs of new energy vehicles, and were prone to failure in harsh environments such as high temperatures and vibrations, requiring regular maintenance and replacement, increasing operating costs. Summary of the Invention

[0004] The purpose of this utility model is to provide a relay distribution board for new energy vehicles.

[0005] To achieve the above objectives, this utility model provides the following technical solution: a relay distribution board for new energy vehicles, comprising a circuit board, wherein the circuit board is provided with a small upper-mount pre-charge relay, a large upper-mount pre-charge relay, an MCU pre-charge relay, a large power distribution pre-charge relay, a drive wiring terminal, a sampling signal terminal, a wiring nut one, a wiring nut two, a wiring nut three, a wiring nut four, a voltage sampling line terminal one, and a voltage divider resistor;

[0006] The small upper-mount pre-charge relay, the large upper-mount pre-charge relay, the MCU pre-charge relay, and the large power distribution pre-charge relay are all connected to the circuit board via voltage sampling line terminal one;

[0007] One pin of the small pre-charge relay is connected to the wiring nut, another pin is connected to the sampling signal terminal through a voltage divider circuit, and the other two pins are connected to the drive wiring terminal through the power supply.

[0008] One pin of the pre-charge relay is connected to the second wiring nut, another pin is connected to the sampling signal terminal through a voltage divider circuit, and the other two pins are connected to the drive wiring terminal through the power supply.

[0009] One pin of the MCU precharge relay is connected to the wiring nut three, another pin is connected to the sampling signal terminal through the voltage divider circuit, and the other two pins are connected to the drive wiring terminal through the power supply.

[0010] One pin of the large power distribution precharge relay is connected to the four wiring nuts, another pin is connected to the sampling signal terminal through the voltage divider circuit, and the other two pins are connected to the drive wiring terminal through the power supply.

[0011] Furthermore, the voltage divider circuit includes resistors R1, R2, R3, and R4 connected in series.

[0012] Furthermore, resistors R1 and R2 are 1MΩ, and resistors R3 and R4 are 750KΩ.

[0013] Furthermore, the circuit board is also provided with voltage sampling line terminal two and voltage sampling line terminal three. Voltage sampling line terminal two is led out through a wire harness and connected to the fast charging positive relay of the new energy vehicle. Voltage sampling line terminal three is led out through a wire harness and connected to the front end of the fast charging negative relay and the main negative relay and the rear end of the main negative relay of the new energy vehicle.

[0014] As can be seen from the above technical solution, this utility model has the following beneficial effects:

[0015] The circuit board has a simple circuit and uses small-package relays for pre-charging, which is compact and reduces the space occupied by the circuit board. The design cycle is short and it can be mass-produced quickly to meet the different power distribution requirements of different vehicle models. It can be compactly laid out on the circuit board, and the height of the relays is moderate, which can be fully matched in the vehicle chassis without blocking or occupying the position of the heat dissipation copper busbar.

[0016] Integrated design reduces the use of wiring harnesses and connectors, lowers weight and space occupation, meeting the lightweight requirements of new energy vehicles; at the same time, the small-volume relay power distribution solution can be used with other circuit boards in different working conditions and environments, adapts to a variety of different chassis, can meet the installation and layout requirements of different vehicle models, has high practicality, and the integrated design effectively reduces design costs and material costs.

[0017] The high voltage is reduced by voltage divider resistors and then connected to the sampling terminal by wires. The subsequent circuit uses a low voltage sampling signal, which has good safety and reliability.

[0018] The precharge relay can be directly soldered and fixed to the board via solder pads, eliminating the need for screws and nuts for fixation and reducing the risk of loosening that screws may cause. Eliminating the steps of tightening screws and adding washers not only reduces material costs but also effectively shortens the production cycle and improves production efficiency. Attached Figure Description

[0019] Figure 1 is a schematic diagram of one side of the circuit board of this utility model;

[0020] Figure 2 is a schematic diagram of the other side of the circuit board of this utility model;

[0021] Figure 3 is a voltage divider circuit diagram of this utility model. Detailed Implementation

[0022] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0023] As shown in Figures 1-3, this utility model provides a relay power distribution board for new energy vehicles, including a circuit board 1. The circuit board is provided with a small upper-mount pre-charge relay 2, a large upper-mount pre-charge relay 3, an MCU pre-charge relay 4, a large power distribution pre-charge relay 5, a drive terminal block 6, a sampling signal terminal block 7, a wiring nut 1 8, a wiring nut 2 9, a wiring nut 3 10, a wiring nut 4 11, a voltage sampling line terminal 1 12, a voltage divider resistor, a voltage sampling line terminal 2 13, and a voltage sampling line terminal 3 14.

[0024] The voltage sampling line terminal 2 13 is led out through the wiring harness and connected to the three fast charging positive relays of the new energy vehicle. The voltage sampling line terminal 3 14 is led out through the wiring harness and connected to the three fast charging negative relays of the new energy vehicle, the front end of the main negative relay (i.e., connected to the negative terminal of the battery pack), and the rear end of the main negative relay (i.e., the vehicle load).

[0025] There are two sampling signal terminals 7. The fast charging positive relay is connected to the voltage dividing resistor through the voltage sampling line terminal 2 13 and the wire to reduce the voltage. After the voltage is reduced to a low voltage, it is connected to the sampling terminal of one of the sampling signal terminals 7 with BAT- as the negative terminal for use by the subsequent circuit. The fast charging negative relay is directly connected to the other sampling signal terminal 7 through the voltage sampling line terminal 3 14 and the wire. The fast charging positive relay is responsible for transmitting the positive current of fast charging, while the fast charging negative relay provides the negative circuit of fast charging, ensuring that the current forms a complete circuit. The fast charging positive relay and the fast charging negative relay cooperate with each other through the voltage sampling line terminal 2 13 and the voltage sampling line terminal 3 14 to ensure that the charging process of the battery is stable and efficient.

[0026] The high voltage is reduced by voltage divider resistors and then connected to the sampling terminal by wires. The subsequent circuit uses a low voltage sampling signal, which has good safety and reliability.

[0027] The small top-mounted pre-charge relay 2, the large top-mounted pre-charge relay 3, the MCU pre-charge relay 4, and the large power distribution pre-charge relay 5 are all connected to the circuit board 1 through voltage sampling line terminal 12; the small top-mounted pre-charge relay 2, the large top-mounted pre-charge relay 3, the MCU pre-charge relay 4, and the large power distribution pre-charge relay 5 are connected to the voltage sampling line terminal 12 on the circuit board 1 through solder pads and copper plating.

[0028] As shown in Figure 3, one pin of the small pre-charge relay 2 is connected to the wiring nut 8, another pin is connected to the sampling signal terminal 7 through the voltage divider circuit, and the other two pins are connected to the drive wiring terminal 6 through the power supply Q+ and Q-.

[0029] One pin of the large pre-charge relay 3 is connected to the wiring nut 2 9, and another pin is connected to the sampling signal terminal 7 through a voltage divider circuit. The other two pins are connected to the drive wiring terminal 6 through the power supply. The circuit diagram is the same as that in Figure 3. The small pre-charge relay 2 in Figure 3 can be replaced with the large pre-charge relay 3.

[0030] One pin of the MCU precharge relay 4 is connected to the wiring nut 3 10, another pin is connected to the sampling signal terminal 7 through the voltage divider circuit, and the other two pins are connected to the drive wiring terminal 6 through the power supply. The circuit diagram is the same as that in Figure 3. The small precharge relay 2 in Figure 3 can be replaced with the MCU precharge relay 4.

[0031] One pin of the large power distribution precharge relay 5 is connected to the wiring nut 4 11, and another pin is connected to the sampling signal terminal 7 through the voltage divider circuit. The other two pins are connected to the drive wiring terminal 6 through the power supply. The circuit diagram is the same as that in Figure 3. The small upper-mounted precharge relay 2 in Figure 3 can be replaced with the large power distribution precharge relay 5.

[0032] The voltage divider circuit includes resistors R1, R2, R3, and R4 connected in series. Resistors R1 and R2 are 1MΩ, and resistors R3 and R4 are 750KΩ. The two 1MΩ resistors and the two 750KΩ resistors divide the high voltage proportionally, while the positive battery voltage (BAT+) is reduced by the five groups of voltage dividers. After voltage division, the voltage is connected to the sampling signal terminal 7 via wires for subsequent circuit processing.

[0033] As shown in Figure 3, the circuit board has a simple design, using a small-package relay for pre-charging. Its compact size reduces the space occupied on the circuit board, allowing for a compact layout. The relay's height is also moderate, ensuring a perfect fit within the vehicle's chassis without obstructing or occupying the space of the heat dissipation copper busbars. The pre-charging relay circuit is designed independently to avoid current surges during high-voltage system power-on, extending the lifespan of high-voltage components. Furthermore, the pre-charging circuit design effectively prevents voltage surges during high-voltage system power-on, reducing the risks of short circuits and arcing, and improving overall vehicle safety. This pre-charging resistor circuit is located on the main relay board and is connected to the pre-charging resistor circuit via a cable connected to the terminal nut 8.

[0034] Integrated design reduces the use of wiring harnesses and connectors, lowering weight and space occupation, meeting the lightweight requirements of new energy vehicles. Meanwhile, the compact relay power distribution solution can be used with other circuit boards in different operating conditions and environments, adapting to various chassis and meeting the installation and layout requirements of different vehicle models. It boasts high practicality, and the integrated design effectively reduces design and material costs.

[0035] This relay distribution board is used in conjunction with the main relay board. The two boards are electrically connected via cables. The main purpose of the power distribution scheme is to control the pre-charging process and avoid the large current surge that occurs during direct connection. When a pre-charging signal is applied to the large power distribution pre-charging relay 5, the large power distribution pre-charging relay 5 closes. Through the terminal nut 411, the pre-charging resistor circuit charges the capacitor of the motor controller to near the battery voltage. After pre-charging is completed, the main relay closes, the large power distribution pre-charging relay 5 opens, and the high-voltage circuit enters normal operating condition.

[0036] When the pre-charge signal is applied to the pre-charge relay 3 of the main equipment, the pre-charge relay 3 of the main equipment closes and connects to the pre-charge resistor circuit through the wiring nut 2 9 to charge the capacitor of the high-power auxiliary equipment. After the pre-charge is completed, the main relay closes, the pre-charge relay 3 of the main equipment opens, and the circuit of the high-power auxiliary equipment enters the normal working state.

[0037] When the precharge signal is applied to the MCU precharge relay 4, the MCU precharge relay 4 closes, and the precharge resistor circuit is connected through the terminal nut 310 to charge the MCU capacitor. After the precharge is completed, the main relay closes, the MCU precharge relay 4 opens, and the MCU circuit enters normal operation.

[0038] When the pre-charge signal is applied to the small upper pre-charge relay 2, the small upper pre-charge relay 2 closes and connects to the pre-charge resistor circuit through the wiring nut 8 to charge the capacitor of the downstream auxiliary equipment. After the pre-charge is completed, the main relay closes, the small upper pre-charge relay 2 opens, and the auxiliary equipment circuit enters the normal working state.

[0039] The PCB consists of vias, pads, mounting holes, wires, resistors, and connectors. The following components are mounted on the PCB according to the circuit design: small top-mount pre-charge relay 2, large top-mount pre-charge relay 3, MCU pre-charge relay 4, large power distribution pre-charge relay 5, drive terminal block 6, sampling signal terminal block 7, wiring nuts 1, 2, 3, 4, 5, voltage sampling line terminal block 1, voltage divider resistor, voltage sampling line terminal block 2, 3, 4, and the voltage sampling lines at various points. The circuits are connected via copper plating on the PCB, reducing the use of cables. Using lightweight relays for pre-charging allows the small top-mount pre-charge relay 2, large top-mount pre-charge relay 3, MCU pre-charge relay 4, and large power distribution pre-charge relay 5 to be directly soldered and fixed to the PCB via pads, eliminating the need for screws and nuts and reducing the risk of loosening that screws may cause. Eliminating the need for screws and washers not only reduces material costs but also effectively shortens the production cycle and improves production efficiency.

[0040] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A relay distribution board for new energy vehicles, comprising a circuit board (1), characterized in that, The circuit board is equipped with a small pre-charge relay (2), a large pre-charge relay (3), an MCU pre-charge relay (4), a large power distribution pre-charge relay (5), a drive terminal (6), a sampling signal terminal (7), a wiring nut one (8), a wiring nut two (9), a wiring nut three (10), a wiring nut four (11), a voltage sampling line terminal one (12), and a voltage divider resistor. The small pre-charge relay (2), the large pre-charge relay (3), the MCU pre-charge relay (4), and the large power distribution pre-charge relay (5) are all connected to the circuit board (1) through the voltage sampling line terminal one (12). One pin of the small pre-charge relay (2) is connected to the wiring nut one (8), and the other pin is connected to the voltage divider resistor. One pin of the circuit is connected to the sampling signal terminal (7), and the other two pins are connected to the drive terminal (6) through the power supply; one pin of the large precharge relay (3) is connected to the second nut (9), and one pin is connected to the sampling signal terminal (7) through the voltage divider circuit, and the other two pins are connected to the drive terminal (6) through the power supply; one pin of the MCU precharge relay (4) is connected to the third nut (10), and one pin is connected to the sampling signal terminal (7) through the voltage divider circuit, and the other two pins are connected to the drive terminal (6) through the power supply; one pin of the large power distribution precharge relay (5) is connected to the fourth nut (11), and one pin is connected to the sampling signal terminal (7) through the voltage divider circuit, and the other two pins are connected to the drive terminal (6) through the power supply.

2. The relay distribution board for new energy vehicles according to claim 1, characterized in that: The voltage divider circuit includes resistors R1, R2, R3, and R4 connected in series.

3. A relay distribution board for new energy vehicles according to claim 2, characterized in that: The resistors R1 and R2 are 1MΩ, and the resistors R3 and R4 are 750KΩ.

4. A relay distribution board for new energy vehicles according to claim 1, characterized in that: The circuit board (1) is also provided with voltage sampling line terminal two (13) and voltage sampling line terminal three (14). Voltage sampling line terminal two (13) is led out through the wire harness and connected to the fast charging positive relay of the new energy vehicle. Voltage sampling line terminal three (14) is led out through the wire harness and connected to the fast charging negative relay, the front end of the main negative relay and the rear end of the main negative relay of the new energy vehicle.

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