High-voltage cable arrangement structure of high-voltage device of hybrid loader
By adopting a wiring scheme that combines a multi-functional controller and cable clamps in the hybrid loader, the problem of unreasonable high-voltage cable layout was solved, achieving the effects of space saving, good heat dissipation, and convenient maintenance.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- QINGDAO LOVOL EXCAVATOR
- Filing Date
- 2025-05-23
- Publication Date
- 2026-05-22
AI Technical Summary
The existing high-voltage cable layout of hybrid loaders is unreasonable, resulting in excessive space occupation, poor heat dissipation, and affecting the overall vehicle failure rate and ease of maintenance.
The wiring scheme adopts a multi-in-one controller and cable clamps. The multi-in-one controller connects to various high-voltage devices, and the cable clamps fix the cables to ensure that the cables run along the shortest path and do not interfere with each other, thus avoiding heat buildup.
It reduces the space occupied by cables, improves the safety and stability of the vehicle, enhances heat dissipation, and facilitates subsequent maintenance.
Smart Images
Figure CN224267046U_ABST
Abstract
Description
Technical Field
[0001] This utility model belongs to the field of engineering machinery, and in particular relates to a high-voltage cable arrangement structure for high-voltage devices of a hybrid loader. Background Technology
[0002] The statements in this section are merely background information related to this utility model and do not necessarily constitute prior art.
[0003] When arranging the high-voltage wiring in a hybrid loader, the safety, reliability, and ease of maintenance of the electrical system must be considered. The wiring includes various electrical components such as batteries, motor controllers, drive motors, and charging interfaces, which are connected via high-voltage wiring harnesses. These high-voltage wiring harnesses must meet specific technical specifications and industry standards to ensure their performance and durability under various operating conditions.
[0004] The current high-voltage line layout uses cable ties and pipe clamps for fixing. Cables are often bundled with cable ties, and their positions are not fixed. This results in significant differences in their condition after assembly in the workshop. In addition, the unreasonable cable routing not only occupies a lot of space, but also causes heat to accumulate in electrical components, affecting heat dissipation and making it easy for the whole vehicle to malfunction, thus affecting the work progress. Utility Model Content
[0005] The purpose of this utility model is to provide a high-voltage cable arrangement structure for high-voltage components of a hybrid loader, so as to solve the problem of unreasonable high-voltage cable arrangement structure in the prior art, realize the need to complete the overall arrangement in the small space of the vehicle, reduce the space occupied by the cable, and at the same time take into account the heat dissipation effect of the electrical components.
[0006] To achieve the above objectives, the present invention adopts the following technical solution:
[0007] This utility model provides a high-voltage cable arrangement structure for high-voltage devices in a hybrid loader, comprising: a multi-function controller, with a generator controller and a generator at the lower end of the multi-function controller, and a working motor and a travel motor respectively located on the lower left and right sides of the generator; a thermal management assembly is located on the left side of the top of the multi-function controller, and a high-voltage box is located on the right side of its top; the multi-function controller is connected to the working motor via a first cable group that bypasses the left side of the generator; the multi-function controller is connected to the travel motor via a second cable group that bypasses the right side of the generator; the multi-function controller is also connected to the high-voltage box at its top via a fourth cable group; the multi-function controller is also connected to the generator controller at the top of the generator via a fifth cable group; the generator controller is connected to the generator via a sixth cable group; the multi-function controller is connected to the battery via a third cable group that bypasses the left side of the generator; and the high-voltage box is connected to the battery thermal management assembly via a seventh cable group.
[0008] Furthermore, the first cable group includes three cables, namely U, V, and W phase high-voltage lines, one end of which is connected to the U, V, and W phase interfaces of the multi-in-one controller, and the other end is connected to the corresponding U, V, and W phase interfaces of the working motor.
[0009] Furthermore, the second cable group includes three cables, namely U, V, and W phase high-voltage cables, one end of which is connected to the corresponding U, V, and W phase interfaces of the multi-in-one controller, and the other end is connected to the U, V, and W phase interfaces of the walking motor.
[0010] Furthermore, the third cable group consists of two cables, one of which is connected to the corresponding interface of the multi-function controller, and the other end of which is connected to the positive terminal of the battery; the other cable is connected to the corresponding interface of the multi-function controller at one end, and grounded at the other end.
[0011] Furthermore, the fourth cable group has two cables, one of which is connected to the positive output terminal of the high-voltage box and the first positive input terminal of the multi-in-one controller at both ends; the other cable is connected to the negative output terminal of the high-voltage box and the first negative input terminal of the multi-in-one controller at both ends.
[0012] Furthermore, the fifth cable group includes two cables, one of which is connected at both ends to the second positive input terminal of the multi-in-one controller and the positive output terminal of the generator controller, respectively; the other cable is connected at both ends to the second negative input terminal of the multi-in-one controller and the negative output terminal of the generator controller, respectively.
[0013] Furthermore, the sixth cable group consists of three U, V, and W three-phase high-voltage lines, one end of which is connected to the U, V, and W phase junction boxes of the generator, and the other end is connected to the corresponding U, V, and W junction boxes of the generator controller, so as to input the three-phase power of the generator to the generator controller.
[0014] Furthermore, the seventh cable group has only one cable, one end of which is connected to the corresponding interface of the high-voltage box, and the other end is connected to the high-voltage interface of the battery thermal management assembly.
[0015] Furthermore, the generator controller transmits the inverter AC power to the multi-function controller via the fifth cable group, and the multi-function controller transmits the three-phase AC power to the first cable group and the second cable group.
[0016] Furthermore, the first cable group and the second cable group are clamped and fixed by cable clamps.
[0017] The technical solution of this utility model has the following beneficial effects:
[0018] 1. By designing the high-voltage cable layout structure, multiple sets of cables are routed in the gaps between electrical components with the shortest possible length, reducing space occupation and preventing mutual interference and heat accumulation.
[0019] 2. By using cable clamps to separate and fix the cables individually, the final mass-produced vehicles will have a more uniform and aesthetically pleasing appearance, and will be easier to maintain in the future.
[0020] 3. The overall wiring of this utility model uses multiple cable clamp groups for fixing, which improves overall reliability and aesthetics compared to fixing schemes using cable ties with seats and pipe clamps.
[0021] The advantages of this invention in additional aspects will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description
[0022] The accompanying drawings, which form part of this specification, are used to provide a further understanding of this utility model. The illustrative embodiments of this utility model and their descriptions are used to explain this utility model and do not constitute an improper limitation of this utility model.
[0023] Figure 1 and Figure 2 This is a schematic diagram of the overall structure of this utility model.
[0024] Figure 3 This is a schematic diagram of the cable structure of this utility model.
[0025] Figure 4 and Figure 5 This is a schematic diagram of the cable clamp assembly structure of this utility model.
[0026] The diagram is labeled as follows: 1. First cable group, 2. Second cable group, 3. Third cable group, 4. Fourth cable group, 5. Fifth cable group, 6. Sixth cable group, 7. Seventh cable group, 8. Cable clamp group, 9. High voltage box, 10. All-in-one controller, 11. Generator, 12. Working motor, 13. Walking motor, 15. Battery thermal management assembly, 16. Generator controller, 91. Mounting plate, 92. Countersunk head, 921. Screw hole, 93. Wire hole, 94. Spacer block, 941. Arc surface, 95. Through groove, 96. Compensation space, 97. Rounded corner, 98. Chamfer. Detailed Implementation
[0027] It should be noted that the following detailed description is exemplary and intended to provide further explanation of the present invention. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.
[0028] It should be noted that the terminology used herein is for the purpose of describing particular implementations only and is not intended to limit the exemplary implementations according to this utility model.
[0029] Where there is no conflict, the embodiments and features in the embodiments of this utility model can be combined with each other.
[0030] This utility model discloses a high-voltage cable arrangement structure for high-voltage components in a hybrid loader; such as Figure 1-3 As shown, the system includes a multi-function controller 10, with a generator controller 16 and a generator 11 at the lower end of the controller 10. A working motor 12 and a walking motor 13 are respectively located on the lower left and right sides of the generator 11. A thermal management assembly is located on the top left side of the controller, and a high-voltage box 9 is located on its top right side. The multi-function controller 10 connects to the working motor 12 via a first cable group 1, bypassing the generator 11 from the left side. The multi-function controller 10 connects to the walking motor 13 via a second cable group 2, bypassing the generator 11 from the right side. The multi-function controller 10 is also connected to the high-voltage box 9 at its top via a fourth cable group 4. The multi-function controller 10 is also connected to the generator controller 16 at the top of the generator 11 via a fifth cable group. The generator controller 16 connects to the generator 11 via a sixth cable group 6. The multi-function controller 10 connects to the battery via a third cable group, bypassing the generator 11 from the left side. The high-voltage box 9 is connected to the battery thermal management assembly 15 via a seventh cable group 7.
[0031] In the specific implementation, the high-voltage box 9, the multi-function controller 10, the generator 11, the working motor 12, the walking motor 13, the battery thermal management assembly 15, and the generator controller 16 are all located inside the controller frame. The controller frame integrates all the above-mentioned high-voltage components, allowing for a reasonable arrangement of each component. Seven cable groups, in conjunction with cable clamp groups 8, ensure that all cables avoid the high-voltage components, and that adjacent cables do not interfere with each other. Cables do not contact the high-voltage components, and at least 20mm of clearance is maintained between adjacent cables or between cables and high-voltage components to prevent vibrations generated during generator 11 operation from causing wear between cables and high-voltage components, thus reducing cable lifespan. The seven cable groups are routed with the shortest possible length within the gaps between the high-voltage components, facilitating later maintenance, reducing space occupation, preventing mutual interference and heat accumulation, and improving overall safety and stability.
[0032] Furthermore, the high-voltage box 9 and the battery thermal management assembly 15 are arranged side by side on the top layer of the controller frame; the multi-in-one controller 10 is located on the second layer in the middle of the controller frame, below the high-voltage box 9 and the battery thermal management assembly 15, and a generator 11 is also arranged below it. A generator controller 16 is arranged on top of the generator 11. The generator 11 is located at the bottom of the controller frame, and a walking motor 13 and a working motor 12 are arranged on the left and right sides of the generator 11.
[0033] In a specific implementation, the all-in-one controller 10 is connected to the working motor 12 via the first cable group 1, and is used to supply power to the working motor 12. Specifically:
[0034] The first cable group 1 includes three cables, namely U, V, and W phase high-voltage lines. One end of each cable is connected to the U, V, and W phase interfaces of the multi-in-one controller 10, and the other end is connected to the corresponding U, V, and W phase interfaces of the working motor 12.
[0035] It should be noted that the U, V, and W phase high-voltage lines are the three phase lines in a three-phase alternating current system, representing the three phases of the three-phase alternating current respectively.
[0036] In a specific implementation, the all-in-one controller 10 is connected to the walking motor 13 via the second cable group 2 to supply power to the walking motor 13. Specifically:
[0037] The second cable group consists of three cables, namely the U, V, and W phase high-voltage lines. One end of each cable is connected to the corresponding U, V, and W phase interfaces of the multi-in-one controller 10, and the other end is connected to the U, V, and W phase interfaces of the walking motor.
[0038] In a specific implementation, the multi-function controller 10 is used to supply power to the battery. The multi-function controller 10 is connected to the battery through a third cable group. The multi-function controller 10 converts high voltage electricity into low voltage electricity. In this embodiment, 600V DC high voltage electricity is converted into 27.5V DC low voltage electricity.
[0039] The third cable group 3 consists of two cables. One cable is connected to the corresponding interface of the multi-function controller 10, and its other end is connected to the positive terminal of the battery. The other cable is connected to the corresponding interface of the multi-function controller 10 at one end and grounded at the other end. Grounding allows the cable to be directly connected to the vehicle frame.
[0040] In a specific implementation, the multi-function controller 10 is connected to the high-voltage box 9 via the fourth cable group 4, specifically:
[0041] The fourth cable group has two cables. One cable is connected to the positive output terminal of the high-voltage box 9 and the first positive input terminal of the multi-function controller 10 at both ends. The other cable is connected to the negative output terminal of the high-voltage box 9 and the first negative input terminal of the multi-function controller 10 at both ends.
[0042] In a specific implementation, the multi-function controller 10 is connected to the generator controller 16 via a fifth cable group, specifically:
[0043] In a specific implementation, the fifth cable group is the high-voltage line of the generator controller 16, which includes two cables. One cable is connected to the second positive input terminal of the multi-in-one controller 10 and the positive output terminal of the generator controller 16 at both ends, respectively; the other cable is connected to the second negative input terminal of the multi-in-one controller 10 and the negative output terminal of the generator controller 16, respectively.
[0044] The generator controller 16 transmits the inverter AC power to the multi-function controller 10 through the fifth cable group 5, and the multi-function controller 10 transmits the three-phase AC power to the first cable group 1 and the second cable group 2.
[0045] In a specific implementation, the generator 11 is connected to the generator controller 16 via a sixth cable group, providing AC power to the generator controller 16. The sixth cable group 6 consists of three U, V, and W phase high-voltage lines, one end of which is connected to the U, V, and W phase junction boxes of the generator 11, and the other end is connected to the corresponding U, V, and W junction boxes of the generator controller 16, thus inputting the three-phase power from the generator 11 to the generator controller 16.
[0046] In a specific implementation, the high-voltage box 9 is connected to the battery thermal management assembly 15 via the seventh cable group 7 to supply power to the battery thermal management assembly 15. The seventh cable group 7 has only one cable, one end of which is connected to the corresponding interface of the high-voltage box 9, and the other end is connected to the high-voltage interface of the battery thermal management assembly 15.
[0047] In a specific implementation, the structure in which the first cable group 1 and the second cable group 2 pass around the left and right sides of the generator 11 can be clamped and fixed by the cable clamp group 8.
[0048] Furthermore, such as Figure 4-5 As shown, the cable clamp 9 includes a mounting plate 91, a countersunk head 92, and wire holes 93. The countersunk head 92 is fixedly installed on both sides of the mounting plate 91. Several wire holes 93 are opened at the lower part of the mounting plate 91 and along the length of the mounting plate 91. Spacers 94 are provided between the wire holes 93. A through groove 95 is opened below the spacers 94, and a compensation space 96 is opened. The compensation space 96 allows the wire holes 93 to be connected.
[0049] A gap is set between the upper surface of the countersunk head 92 and the upper surface of the mounting plate 91. A screw hole 921 is opened through the countersunk head 92. The axis of the screw hole 921 is perpendicular to the upper surface of the countersunk head 92. The countersunk head is used on both sides, which can reduce the overall height of the pipe clamp, reduce the space required for installation, and make room for the height of the rest of the vehicle layout.
[0050] The clearance between the upper surface of the countersunk head 92 and the upper surface of the mounting plate 91 allows for disassembly from the side using a regular wrench, without the need for a specific socket, thus improving efficiency during maintenance and disassembly.
[0051] A fillet 97 is provided at the connection between the mounting plate 91 and the countersunk head 92. Since the connection between the mounting plate and the countersunk head 92 is a location with high stress concentration, the fillet 97 is provided to avoid stress concentration at the sharp corner of the connection between the mounting plate 91 and the countersunk head 92.
[0052] The lower end of the spacer 94 is provided with an arc surface 941. Since the cable will come into contact with the tip of the bottom end of the spacer 94 during installation, in order to avoid cable wear, an arc surface 941 is provided at the tip of the lower end of the spacer 94, thereby preventing the lower end of the spacer 94 from scratching the cable sheath.
[0053] Mounting plate 91 has a rectangular cross-section, countersunk head 92 has a rectangular cross-section, and the countersunk head 92 has a chamfer 98 on its side.
[0054] The countersunk head 92 and the mounting plate 91 are made of stainless steel, which improves the tensile strength and yield strength of the fixed pipe clamp.
[0055] The countersunk head 92 and the mounting plate 91 are integrated. The countersunk head 92 is welded to both sides of the mounting plate 91, and then the corner radius 97 is machined at the connection between the countersunk head 92 and the mounting plate 91.
[0056] The wire hole 93 is a semi-circular hole. Multiple wire holes 93 are evenly arranged along the length of the mounting plate 91. The number of wire holes 93 can be determined during processing according to the number of cables to be fixed.
[0057] When machining the wire hole 93, it can be machined in the width direction of the mounting plate 91 using the existing drilling and milling method. After machining the wire hole 93, a spacer block 94 is formed between each wire hole 93. Then, drilling and milling are performed on the spacer block 94 in the width direction of the mounting plate 91. The height of the spacer block 94 is half the radius of the wire hole 93. After the spacer block 94 is removed, a space is left at the position where the spacer block 94 is removed.
[0058] During cable installation, the cable is placed in the cable hole 93. If the cable diameter is larger than the diameter of the cable hole 93, a portion of the cable sidewall will be within the compensation space 96 after installation, ensuring that even larger diameter cables can be smoothly installed in the mounting hole. The cable is then secured to the loader body or attachments by bolts passing through the screw holes 921. Each cable can be placed in one cable hole. Appropriate cable clamps 8 can be selected based on the number and size of the cables to achieve cable fixation.
[0059] Taking the fixing of the first cable group 1 and the second cable group 2 as an example, the specific method of fixing the cable in the cable clamp group 8 is explained. The other cable groups are the same and will not be described in detail.
[0060] The six cables of the first cable group 1 and the second cable group 2 are sequentially placed into the multiple holes 93 of a cable clamp group 8. The cable clamp group 8 consists of two mirror-image cable clamps, namely the first cable clamp and the second cable clamp. After placing the cables into the holes of the first cable clamp, the second cable clamp is connected to the first cable clamp group, so that each cable is accommodated in the cable clamp group 8. Then, bolts are used to fix the cables in place through the corresponding screw holes 921 of the two cable clamp groups 8.
[0061] The cable clamp group 8 is arranged horizontally, which can fix the cable while allowing the rest of the cable to pass through the cable hole 93, thus avoiding the cable crossing and mess during the routing.
[0062] Working principle of this utility model:
[0063] like Figure 3 As shown, a six-hole cable clamp group 8 is used to fix the first cable group 1 and the second cable group 2 at the outlet of the high-voltage box 9. Two three-hole cable clamp groups 8 are used to fix the first cable group 1 on the top of the generator 11. Another three-hole cable clamp group 8 is used to fix the first cable group 1 on the right side of the generator 11. A third three-hole cable clamp group 8 is used to fix the second cable group 2 on the top of the generator 11. A fourth three-hole cable clamp group 8 is used to fix the second cable group 2 on the left side of the generator 11. This causes the first cable group 1 and the second cable group 2 to bend and run from the left and right sides of the generator 11 respectively, without contacting the generator 11. The wiring is clear and saves space. The third cable group 3 is fixed with a pipe clamp, etc., so that it bypasses the generator 11 and does not contact the generator 11 or other high-voltage devices. The fourth cable group 4 runs from the bottom of the multi-function controller 10 and is fixed with a pipe clamp, etc., so that it avoids the bottom of the multi-function controller and the top of the generator 11. The fifth cable group 5 is fixed with a pipe clamp, etc., so that it runs from the top of the generator 11 and avoids the generator 11 and the generator controller 16. The sixth cable group 6 is secured using a three-hole cable clamp assembly 8, and runs from the top of the generator 11, ensuring that the sixth cable group 6, except for its connection to the generator control interface, does not contact any other part of the generator controller 16. The seventh cable group is secured along the top edge of the controller frame, ensuring that the seventh cable group, except for its connection to the corresponding interface, does not contact any other part of the high-voltage box 9 or the battery thermal management assembly 15.
[0064] It should be noted that when arranging high-voltage cables, this utility model should ensure that the shortest cable connection is used, that two adjacent cables do not interfere with each other, that the cables do not contact the starting components, and that there is at least a 20mm gap between adjacent cables or between cables and electrical components, in order to avoid vibrations generated when the generator 11 is working, which could cause cable wear and reduce cable life.
[0065] Although the specific embodiments of the present utility model have been described above in conjunction with the accompanying drawings, this is not intended to limit the scope of protection of the present utility model. Those skilled in the art should understand that various modifications or variations that can be made by those skilled in the art without creative effort based on the technical solution of the present utility model are still within the scope of protection of the present utility model.
Claims
1. A high-voltage cable arrangement structure for high-voltage components of a hybrid loader, characterized in that, The device includes a multi-function controller, with a generator controller and a generator located at the lower end of the controller. A working motor and a travel motor are respectively located on the lower left and right sides of the generator. A thermal management assembly is located on the top left side of the multi-function controller, and a high-voltage box is located on its top right side. The multi-function controller connects to the working motor via a first cable group, bypassing the generator from the left side. It also connects to the travel motor via a second cable group, bypassing the generator from the right side. Furthermore, the multi-function controller is connected to the high-voltage box at its top via a fourth cable group. It further connects to the generator controller at the top of the generator via a fifth cable group. The generator controller is connected to the generator via a sixth cable group. Finally, the multi-function controller connects to the battery via a third cable group, bypassing the generator from the left side. The high-voltage box is connected to the battery thermal management assembly via a seventh cable group.
2. The high-voltage cable arrangement structure of a high-voltage device for a hybrid loader as described in claim 1, characterized in that, The first cable group includes three cables, namely U, V, and W phase high-voltage lines. One end of each cable is connected to the U, V, and W phase interfaces of the multi-in-one controller, and the other end is connected to the corresponding U, V, and W phase interfaces of the working motor.
3. The high-voltage cable arrangement structure of a high-voltage device for a hybrid loader as described in claim 1, characterized in that, The second cable group includes three cables, namely the U, V, and W phase high-voltage lines. One end of each cable is connected to the corresponding U, V, and W phase interfaces of the multi-in-one controller, and the other end is connected to the U, V, and W phase interfaces of the walking motor.
4. The high-voltage cable arrangement structure of the high-voltage device for a hybrid loader as described in claim 1, characterized in that, The third cable group consists of two cables. One cable is connected to the corresponding interface of the multi-function controller, and its other end is connected to the positive terminal of the battery. The other cable is connected to the corresponding interface of the multi-function controller at one end and grounded at the other end.
5. The high-voltage cable arrangement structure of a high-voltage device for a hybrid loader as described in claim 1, characterized in that, The fourth cable group has two cables. One cable is connected to the positive output terminal of the high-voltage box and the first positive input terminal of the multi-in-one controller at both ends. The other cable is connected to the negative output terminal of the high-voltage box and the first negative input terminal of the multi-in-one controller at both ends.
6. The high-voltage cable arrangement structure of a high-voltage device for a hybrid loader as described in claim 1, characterized in that, The fifth cable group includes two cables, one of which is connected to the second positive input terminal of the multi-in-one controller and the positive output terminal of the generator controller at both ends; the other cable is connected to the second negative input terminal of the multi-in-one controller and the negative output terminal of the generator controller at both ends.
7. The high-voltage cable arrangement structure of a high-voltage device for a hybrid loader as described in claim 1, characterized in that, The sixth cable group consists of three U, V, and W three-phase high-voltage lines. One end of the cable is connected to the U, V, and W phase junction boxes of the generator, and the other end is connected to the corresponding U, V, and W junction boxes of the generator controller, so as to input the three-phase power of the generator to the generator controller.
8. The high-voltage cable arrangement structure of a high-voltage device for a hybrid loader as described in claim 1, characterized in that, The seventh cable group has only one cable, one end of which is connected to the corresponding interface of the high-voltage box, and the other end is connected to the high-voltage interface of the battery thermal management assembly.
9. The high-voltage cable arrangement structure of a high-voltage device for a hybrid loader as described in claim 1, characterized in that, The generator controller transmits the inverter AC power to the multi-function controller via the fifth cable group, and the multi-function controller transmits the three-phase AC power to the first cable group and the second cable group.
10. The high-voltage cable arrangement structure of a high-voltage device for a hybrid loader as described in claim 1, characterized in that, The first cable group and the second cable group are clamped and fixed by cable clamps.