Distribution board structure

Abstract

This utility model discloses a power distribution board structure, including a power distribution board body, electrical connection components disposed on the power distribution board body, and a cover structure. It also includes: a bent copper busbar disposed on the power distribution board body for carrying current; a power distribution board partition installed inside the power distribution board body for fixing the bent copper busbar and physically isolating the electrical connection components; and a multi-layer waterproof structure installed on the power distribution board body, which, together with the cover structure, seals the internal space of the power distribution board body to prevent moisture from entering. In this utility model, a single bent copper busbar replaces traditional solder joints, improving current carrying capacity and reducing heat generation; the symmetrical layout and foolproof partition ensure wire harness isolation, compact wiring, and quick assembly and disassembly; further enhanced by a triple seal of potting compound, O-rings, and upper and lower waterproof gaskets, achieving all-weather waterproofing, shockproofing, and arc-proofing, fully meeting the high-power, high-reliability, and easy-to-maintain operational requirements of heavy-duty drones.

Description

Technical Field

[0001] This utility model relates to the field of drone accessories technology, and in particular to the structure of a power distribution board. Background Technology

[0002] With the rapid development of drone technology, heavy-duty drones, such as those used for agricultural plant protection, are increasingly widely used in fields like logistics and transportation. These drones are typically equipped with multi-axis power systems, requiring the rational and safe distribution of the high current output from the lithium battery to each power unit, while simultaneously transmitting critical signals such as voltage and current back to the flight controller in real time for precise control and fault monitoring. The power distribution board, as a core component connecting the battery, motors, and flight controller, directly determines the overall operating efficiency, safety, and reliability of the drone through its electrical performance, structural layout, and protection level.

[0003] The current power distribution boards used in agricultural or heavy-load drones generally have the following shortcomings:

[0004] First, traditional power distribution boards often use narrow copper foil or thin wires as current paths, which limits the cross-sectional area and cannot meet the continuous operating current requirements of heavy-duty drones, which can easily reach hundreds of amperes. This causes the copper foil to heat up and the voltage drop to increase, which not only affects the power output, but may also cause overheating and burnout in severe cases, reducing operating efficiency and posing safety hazards.

[0005] Secondly, agricultural drones often operate in open, humid, or rainy environments. Existing power distribution boards are mostly simple plastic shells secured with screws, lacking effective sealing structures at the shell seams, plug roots, and wiring harness exits, allowing rainwater to easily seep in. This can lead to minor issues like circuit corrosion and signal drift, or more serious problems like short circuits that burn out the flight controller or battery, severely impacting drone safety.

[0006] Therefore, a power distribution board structure is provided to meet the growing performance and safety requirements of heavy-duty drones. Utility Model Content

[0007] The purpose of this utility model is to propose a power distribution board structure to solve the above-mentioned problems.

[0008] To achieve the above objectives, this utility model adopts the following technical solution: a power distribution board structure, including a power distribution board body, electrical connection components disposed on the power distribution board body, and a cover structure, further comprising:

[0009] A bent copper busbar is installed on the main body of the distribution board to carry current;

[0010] The power distribution board partition is installed inside the power distribution board body to fix the bent copper busbar and physically isolate the electrical connection components;

[0011] A multi-layer waterproof structure is installed on the main body of the power distribution board, and together with the cover structure, it seals the internal space of the main body of the power distribution board to prevent moisture from entering the interior of the main body of the power distribution board.

[0012] Preferably, the bent copper busbar is composed of a copper alloy plate that is bent into shape as a whole, and includes: a positive terminal, a positive power supply terminal, a negative terminal, and a negative power supply terminal;

[0013] The positive terminal of the power supply and the positive terminal are fastened to the positive terminal busbar cavity of the main body of the power distribution board by bolts, so as to realize the electrical connection with the positive branch of the electrical connection component;

[0014] The negative terminal of the power supply and the negative terminal are fastened to the negative terminal busbar cavity of the main body of the power distribution board by bolts, so as to realize the electrical connection with the negative terminal branch of the electrical connection component.

[0015] Preferably, the power distribution plate has a centrally symmetrical structure, and an insulating rib is formed between the positive and negative current-carrying cavities to maintain electrical isolation between the positive and negative power supplies.

[0016] Preferably, the cover structure includes a top cover for the power distribution plate and a cover plate for the power distribution plate, both of which are locked to the main body of the power distribution plate by bolts distributed circumferentially.

[0017] Preferably, the upper surface of the power distribution board partition is provided with a foolproof protrusion, and the power distribution board cover is provided with a corresponding foolproof notch. The foolproof protrusion and the foolproof notch are complementary in shape, thus defining the installation direction of the power distribution board cover.

[0018] Preferably, the electrical connection assembly includes:

[0019] The power plug passes through the top cover of the power distribution board and extends into the main body of the power distribution board;

[0020] The power harness and the power conversion harness are respectively crimped to the positive and negative terminals of the corresponding bent copper busbars via silicone wires;

[0021] The main control board wiring harness is electrically connected to the power plug and led out to the external flight controller.

[0022] Preferably, the multi-layer waterproof structure includes:

[0023] The upper and lower waterproof pads are respectively sandwiched around both sides of the main body of the power distribution board, forming opposing elastic compression sealing rings to prevent water from seeping in.

[0024] An O-ring is provided between the mating surfaces of the upper cover of the distributor plate and the main body of the distributor plate to seal the circumferential gap between the upper cover of the distributor plate and the main body of the distributor plate.

[0025] A plug sealing ring is disposed between the power plug and the top cover of the power distribution plate to seal the annular gap between the power plug and the top cover of the power distribution plate.

[0026] Preferably, the mating surface of the distributor plate cover is provided with a U-shaped groove, and the O-ring is embedded in the U-shaped groove and deforms to achieve a seal when pressed.

[0027] In summary, due to the adoption of the above technical solution, the beneficial effects of this utility model are:

[0028] 1. This application uses a bent copper busbar to form a single piece of copper alloy, eliminating traditional solder joints and multiple overlaps, reducing contact resistance and heat generation, enhancing the current carrying capacity of the circuit board, meeting the high power requirements of heavy-duty UAVs, and avoiding efficiency reduction or safety hazards caused by insufficient current.

[0029] 2. This application uses a symmetrical layout design to physically isolate the power harness from the power conversion harness, making the wiring clear and orderly, reducing space occupation, and the foolproof structure of the power distribution board further simplifies the disassembly and assembly process and reduces maintenance difficulty.

[0030] 3. This application achieves reliable operation in rainy weather by using a potting process, O-rings, and upper and lower waterproof gaskets for triple protection, eliminating the risk of short circuits or burnout. Attached Figure Description

[0031] Figure 1 A schematic diagram of the power distribution board structure provided according to an embodiment of the present invention is shown;

[0032] Figure 2 A schematic diagram of the current-carrying structure of the power distribution board according to an embodiment of the present invention is shown;

[0033] Figure 3 An exploded view of the circuit board structure provided according to an embodiment of the present invention is shown;

[0034] Figure 4 A schematic diagram of the structure of the lower waterproof pad provided according to an embodiment of the present invention is shown;

[0035] Figure 5 A schematic diagram of the upper waterproof pad structure according to an embodiment of the present invention is shown;

[0036] Figure 6 A schematic diagram of the structure of the power distribution plate partition provided according to an embodiment of the present utility model is shown.

[0037] Legend:

[0038] 1. Main body of the power distribution board; 2. Power plug; 3. Main control board connection harness; 4. Negative terminal; 5. Negative power supply terminal; 6. Positive terminal; 7. Positive power supply terminal; 8. Power harness; 9. Power adapter harness; 10. Power distribution board cover; 11. O-ring seal; 12. Plug seal; 13. Lower waterproof gasket; 14. Power distribution board partition; 15. Upper waterproof gasket; 16. Power distribution board cover. Detailed Implementation

[0039] 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 skilled in the art without creative effort are within the protection scope of the present utility model.

[0040] Please see Figures 1-6 This utility model provides a technical solution: a power distribution board structure, including a power distribution board body 1, electrical connection components disposed on the power distribution board body 1, and a cover structure, and further including:

[0041] The bent copper busbar is installed on the main body 1 of the power distribution board to carry current. As the main current channel of the power distribution board, the bent copper busbar can carry a continuous current of up to 360A at the same time. By symmetrically arranging the circuit, the circuit length is shortened, the impedance and heat generation are reduced, and the stable power supply of the heavy-duty UAV power system is ensured.

[0042] The power distribution board partition 14 is installed inside the power distribution board body 1 to fix the bent copper busbar and physically isolate the electrical connection components; the power distribution board partition 14 forms a physical isolation wall for the positive and negative terminal busbar cavities to prevent accidental bridging by tools or screws that could cause a short circuit.

[0043] A multi-layer waterproof structure is installed on the main body 1 of the power distribution board, and together with the cover structure, it seals the internal space of the main body 1 of the power distribution board to prevent moisture from entering the interior of the main body 1 of the power distribution board.

[0044] The multi-layered waterproof structure can prevent rainwater, moisture and condensation from entering, ensuring that the circuit board can still operate safely in outdoor rainy environments.

[0045] Specifically, such as Figures 1-3 As shown, the bent copper busbar is composed of a copper alloy plate bent into shape as a whole, including: electrical positive terminal 6, power positive terminal 7, electrical negative terminal 4, and power negative terminal 5. The bent copper busbar is continuously bent to form a "Z" or "U" shaped three-dimensional structure, reducing overlaps and solder joints. According to the empirical formula for copper busbar current carrying capacity: Current carrying capacity (A) = 8 * copper busbar cross-sectional area (mm²), the cross-sectional area of ​​the bent copper busbar is ≥45mm², and according to the empirical formula, it can continuously carry a current of over 360A.

[0046] The positive power supply 7 and the positive terminal 6 are fastened to the positive current busbar cavity of the main body of the power distribution board 1 by bolts, realizing the electrical connection with the positive branch of the electrical connection component; the positive power supply 7 is directly bolted to the positive input terminal of the battery, which serves as the main current inlet; the positive terminal 6 distributes the positive branch to each axis motor; and M5 / M6 crimp nuts are reserved for easy parallel connection of 7AWG silicone wire.

[0047] The negative terminal 5 and the negative terminal 4 are fastened to the negative terminal busbar cavity of the main body 1 of the power distribution board by bolts, so as to realize the electrical connection with the negative terminal branch of the electrical connection component.

[0048] The negative terminal 5 of the power supply serves as the entry point for the negative current of the battery, connecting the return current to the distribution board; the negative terminal 4 of the electrical terminal distributes the collected negative current to each axis motor, forming a complete return path.

[0049] The distributor plate 14 has a centrally symmetrical structure and forms an insulating rib between the positive and negative current-carrying cavities to maintain electrical isolation between the positive power supply 7 and the negative power supply 5.

[0050] The distributor plate partition 14, through its centrally symmetrical structure and insulating ribs, forms a physical isolation wall between the positive and negative busbar cavities, preventing short circuits caused by screws or metal shavings. The distributor plate partition 14 also serves as a copper busbar positioning bracket, ensuring consistent spacing between the copper busbars and further improving reliability.

[0051] Specifically, such as Figure 1 , Figure 3 , Figure 4 and Figure 5 As shown, the cover structure includes a power distribution plate cover 10 and a power distribution plate cover 16, both of which are locked to the power distribution plate body 1 by circumferentially distributed bolts.

[0052] The upper surface of the distributor plate 14 is provided with a foolproof protrusion, and the distributor plate 16 is provided with a corresponding foolproof notch. The shapes of the foolproof protrusion and the foolproof notch are complementary, which limits the installation direction of the distributor plate 16.

[0053] Both the top cover 10 and the cover plate 16 of the power distributor are fixed to the main body 1 of the power distributor by bolts, forming an upper and lower opposing clamping structure, making the interior of the main body 1 of the power distributor a closed cavity, which is convenient for disassembly and assembly and ensures the overall rigidity.

[0054] The design of the foolproof structure ensures a high assembly pass rate. During the assembly of the distributor cover 16, if the assembly direction of the distributor cover 16 is incorrect, the foolproof boss and the notch will not align, resulting in misalignment of the bolt holes. This prevents the bolts from being tightened further, thereby reducing the risk of reverse installation and preventing uneven compression of the sealing gasket due to reverse installation, which could lead to waterproofing failure.

[0055] Specifically, such as Figures 1-3 As shown, the electrical connection assembly includes:

[0056] The power plug 2 passes through the top cover 10 of the power distributor board and extends into the main body 1 of the power distributor board. The power plug 2 passes through the top cover 10 of the power distributor board, with its head exposed and its tail extending into the main body 1 of the power distributor board. It is locked with bolts through the positive power terminal 7 and the negative power terminal 5 to achieve high current input. At the same time, its signal pins are crimped to the main control board connection harness 3, and the output voltage / current sampling signal is sent to the external flight controller, forming the interface between the battery and the power distributor board.

[0057] The power harness 8 and the power conversion harness 9 are respectively crimped to the positive and negative terminals of the corresponding bent copper busbars via silicone wires;

[0058] The power harness 8 provides a high-current power circuit to each axis motor; heavy-duty drones usually carry two batteries, so there are two power distribution boards, and the power adapter harness 9 is used to connect the batteries on the two power distribution boards in parallel to improve the drone's endurance.

[0059] The main control board connection harness 3 is electrically connected to the power plug 2 and leads out to the external flight controller. The main control board connection harness 3 includes a power supply harness and a signal harness. One end is crimped to the internal pins of the power plug 2, and the other end is led out to the external flight controller via a shielded twisted pair cable. It can transmit total voltage and total current signals in real time, enabling the flight controller to perform power estimation, overcurrent protection, and fault diagnosis.

[0060] Specifically, such as Figures 1-5 As shown, the multi-layer waterproof structure includes:

[0061] The upper waterproof pad 15 and the lower waterproof pad 13 are respectively sandwiched around the two sides of the main body 1 of the power distribution board, forming opposing elastic compression sealing rings to block the infiltration of water.

[0062] When the bolts lock the distributor cover 16 onto the distributor body 1, the upper waterproof pad 15 and the lower waterproof pad 13 are squeezed and deformed to prevent rainwater from entering the distributor through the gap between the distributor body 1 and the distributor cover 16, thus achieving waterproof protection for the internal power harness 8 and power conversion harness 9.

[0063] The O-ring 11 is disposed between the mating surfaces of the upper cover 10 of the distributor plate and the main body 1 of the distributor plate, and seals the circumferential gap between the upper cover 10 of the distributor plate and the main body 1 of the distributor plate.

[0064] When the bolts tighten the distributor plate cover 10 and the distributor plate body 1, the O-ring seal 11 is squeezed and deformed, forming a continuous line seal along the circumference, sealing the gap between the distributor plate cover 10 and the distributor plate body 1, thereby preventing moisture from seeping into the interior of the distributor plate from the joint.

[0065] The plug sealing ring 12 is disposed between the power plug 2 and the distributor plate cover 10 to seal the annular gap between the power plug 2 and the distributor plate cover 10.

[0066] When the power plug 2 is inserted into place, the plug sealing ring 12 is compressed, generating a uniform radial rebound force, thereby sealing the annular gap between the power plug 2 and the hole wall of the distributor plate cover 10, preventing rainwater, fog or dust from entering the inside of the distributor plate through the gap between the plug and the distributor plate cover 10.

[0067] The power plug 2, the negative terminal 4, and the positive terminal 6 are placed into the adhesive chamber formed by the top cover 10 of the distributor plate and the sealing ring. After vacuuming, high-elastic insulating adhesive is injected and cured to further block the intrusion of external moisture.

[0068] The mating surface of the distributor plate cover 10 is provided with a U-shaped groove, and the O-ring seal 11 is embedded in the U-shaped groove and deforms to achieve a seal when pressed.

[0069] The U-shaped groove positions the O-ring 11. When locked, the side wall of the groove restricts the slippage of the O-ring 11, so that it only produces controllable compression deformation, forming a uniform circumferential line seal, preventing the seal from misaligning and failing, and ensuring that the gap between the top cover and the main body is reliably sealed.

[0070] The above description of the embodiments enables those skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A structure of a power distribution panel, comprising a power distribution panel main body (1), an electrical connection assembly provided on the power distribution panel main body (1), and a cover structure, characterized in that, Also includes: A bent copper busbar is installed on the main body (1) of the distribution board to carry current; The power distribution board partition (14) is installed inside the power distribution board body (1) to fix the bent copper busbar and physically isolate the electrical connection components; A multi-layer waterproof structure is installed on the main body (1) of the power distribution board, and together with the cover structure, it seals the internal space of the main body (1) of the power distribution board to prevent moisture from entering the interior of the main body (1).

2. The power distribution panel structure of claim 1, wherein The bent copper busbar is composed of a copper alloy plate bent into shape as a whole, including: electrical terminal positive (6), power supply positive (7), electrical terminal negative (4) and power supply negative (5). The positive terminal of the power supply (7) and the positive terminal of the terminal (6) are fastened to the positive terminal busbar cavity of the main body of the power distribution board (1) by bolts, so as to realize the positive terminal branch electrical connection with the electrical connection component; The negative terminal of the power supply (5) and the negative terminal (4) are fastened to the negative terminal busbar cavity of the main body of the power distribution board (1) by bolts, so as to realize the electrical connection with the negative terminal branch of the electrical connection component.

3. The distributor structure according to claim 2, characterized in that, The power distribution plate partition (14) has a centrally symmetrical structure and forms an insulating rib between the positive and negative power junctions to maintain electrical isolation between the positive power supply (7) and the negative power supply (5).

4. The power panel structure of claim 1, wherein The cover structure includes a power distribution plate cover (10) and a power distribution plate cover (16), both of which are locked to the power distribution plate body (1) by circumferentially distributed bolts.

5. The power panel structure of claim 4, wherein, The upper surface of the power distribution plate partition (14) is provided with a foolproof protrusion, and the power distribution plate cover (16) is provided with a corresponding foolproof notch. The foolproof protrusion and the foolproof notch are complementary in shape, which limits the installation direction of the power distribution plate cover (16).

6. The power panel structure of claim 4, wherein, The electrical connection assembly includes: The power plug (2) passes through the cover (10) of the power distribution board and extends into the body (1) of the power distribution board; The power harness (8) and the power conversion harness (9) are respectively crimped to the positive and negative terminals of the corresponding bent copper busbars via silicone wires; The main control board connection harness (3) is electrically connected to the power plug (2) and led out to the external flight controller.

7. The power panel structure of claim 4, wherein The multi-layer waterproof structure includes: The upper waterproof pad (15) and the lower waterproof pad (13) are respectively sandwiched around the two sides of the main body of the distribution board (1) to form opposing elastic compression sealing rings to block the infiltration of water. An O-ring (11) is provided between the mating surfaces of the upper cover (10) of the power distribution plate and the main body (1) of the power distribution plate to seal the circumferential gap between the upper cover (10) of the power distribution plate and the main body (1) of the power distribution plate; A plug sealing ring (12) is provided between the power plug (2) and the top cover of the power distribution plate (10) to seal the annular gap between the power plug (2) and the top cover of the power distribution plate (10).

8. The power panel structure of claim 7, wherein, The mating surface of the top cover (10) of the power distribution plate is provided with a U-shaped groove, and the O-ring (11) is embedded in the U-shaped groove and deforms to achieve sealing when pressed.

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