Power distribution unit

Abstract

This application relates to a power distribution unit, comprising: a housing including a bottom wall and a side wall that jointly define a mounting cavity, the side wall having a first wall and a second wall disposed opposite to each other along a first direction; a charging connector mounted on the first wall, and a positive battery connector and a negative battery connector mounted on the second wall and arranged sequentially along a second direction intersecting the first direction; a positive relay, a fuse, a direct current bus, a negative relay, and a first current bus, all mounted within the mounting cavity; the positive relay, fuse, and positive battery connector are directly opposite each other along the first direction, and the positive terminal of the charging connector, the positive relay, the direct current bus, the fuse, and the positive battery connector are sequentially electrically connected; the negative relay and the negative battery connector are spaced apart along the second direction on the same side of the positive relay, and the negative terminal of the charging connector, the negative relay, the first current bus, and the negative battery connector are sequentially electrically connected.

Description

Technical Field

[0001] This application relates to the field of power distribution technology, and in particular to a power distribution unit. Background Technology

[0002] As energy storage units for electrical devices (including electric vehicles and aircraft), power batteries play a crucial role in providing power to various electrical components within these devices. Because power batteries have high voltage and high power, they also pose certain risks. To ensure the safe operation of electrical devices, power batteries are typically equipped with power distribution units (PDUs) to control the charging and discharging process and prevent risks such as overload and short circuits.

[0003] A power distribution unit typically includes a enclosure, electrical components (including fuses and relays), and connectors. The electrical components are installed inside the enclosure, while the connectors are mounted on the enclosure walls. The connectors are electrically connected to the fuses and relays and are used to connect to external electrical connection structures. In traditional technologies, the layout of the electrical components inside the enclosure and / or the placement of the connectors on the enclosure walls are often inefficient, resulting in a large footprint for the power distribution unit. Utility Model Content

[0004] Therefore, it is necessary to provide a power distribution unit with a reasonable layout to reduce the footprint of traditional power distribution units, which addresses the problem of large footprint of traditional power distribution units.

[0005] On one hand, this application provides a power distribution unit, including:

[0006] The housing includes a bottom wall and a side wall that together define a mounting cavity, the side wall having a first wall and a second wall disposed opposite to each other along a first direction;

[0007] The charging connector installed on the first wall, the positive battery connector and the negative battery connector are both installed on the second wall and are arranged sequentially along the second direction intersecting the first direction;

[0008] The positive relay, fuse, direct current busbar, negative relay, and first busbar are all installed in the mounting cavity;

[0009] The positive relay, the fuse, and the positive battery connector are aligned along the first direction, and the positive terminal of the charging connector, the positive relay, the direct current bus, the fuse, and the positive battery connector are sequentially electrically connected; the negative relay and the negative battery connector are spaced apart along the second direction on the same side of the positive relay, and the negative terminal of the charging connector, the negative relay, the first current bus, and the negative battery connector are sequentially electrically connected.

[0010] In one embodiment, the first conductive bus includes a first conductive segment and a second conductive segment that are electrically connected to each other;

[0011] The first conductive segment is electrically connected to the negative relay and extends along the second direction toward the positive relay, and the second conductive segment extends along the first direction to be electrically connected to the negative battery connector.

[0012] In one embodiment, the power distribution unit further includes a pre-charge relay and a pre-charge resistor installed in the mounting cavity, the pre-charge relay and the pre-charge resistor being opposite each other along the first direction and located between the negative relay and the positive relay along the second direction;

[0013] The precharge relay and the precharge resistor are connected in series, and both are electrically connected to the two ends of the positive relay, respectively.

[0014] In one embodiment, the positive relay, the negative relay, the precharge relay, and the precharge resistor are all mounted on the bottom wall;

[0015] The direct-drive busbar, the fuse, and the first busbar are suspended above the bottom wall in a third direction;

[0016] The first direction, the second direction, and the third direction intersect each other.

[0017] In one embodiment, the power distribution unit further includes a communication connector mounted on the second wall, wherein the negative battery connector is located between the communication connector and the positive battery connector along the second direction;

[0018] The charging connector and the communication connector are electrically connected via a communication cable.

[0019] In one embodiment, the power distribution unit includes a positive high-voltage cable and a negative high-voltage cable;

[0020] The positive high-voltage cable connects the positive terminal and the positive relay, and the negative high-voltage cable connects the negative terminal and the negative relay;

[0021] One end of the communication cable connected to the charging connector is spaced apart from both the positive high-voltage cable and the negative high-voltage cable along a third direction.

[0022] The first direction, the second direction, and the third direction intersect each other.

[0023] In one embodiment, the positive relay is offset from the charging connector along the first direction, and the positive high-voltage cable includes a first part and a second part that are connected to each other. The first part is connected to the positive terminal and extends along the first direction, and the second part is deflected relative to the first part in a direction away from the negative relay to be connected to the positive relay.

[0024] The negative relay is opposite the charging connector along the first direction, and the negative high-voltage cable extends along the first direction to connect the negative terminal and the negative relay.

[0025] In one embodiment, the power distribution unit further includes a control line and a data acquisition line, and both the positive relay and the negative relay are connected to the communication connector through the control line and the data acquisition line;

[0026] The power distribution unit further includes a first cable, and the communication cable, the control line and the acquisition line are connected to the communication connector through the first cable.

[0027] In one embodiment, the communication cable and the control line and the acquisition line connected to the positive relay converge to the connector and are connected to the first cable through the connector;

[0028] The control line and the acquisition line connected to the negative relay are directly connected to the first cable.

[0029] In one embodiment, the sidewall includes a third wall and a fourth wall disposed opposite each other along a third direction, the third wall being disposed close to the negative relay relative to the fourth wall;

[0030] The first wall, the third wall, the second wall, and the fourth wall are connected in sequence, and the first direction, the second direction, and the third direction intersect each other.

[0031] The power distribution unit includes a wire harness clip and a connector bracket disposed on the inner side of the third wall. Two wire harness clips are disposed on both sides of the connector bracket along a first direction. The connector is constrained by the connector bracket. The communication cable is constrained to one side of the connector by the wire harness clip, and the first cable is constrained to the other side of the connector by the other wire harness clip.

[0032] Compared with the prior art, this application has the following beneficial effects:

[0033] In this application, the power distribution unit has a charging connector mounted on the first wall, while the positive and negative battery connectors are mounted on the second wall and spaced apart along a second direction. This is equivalent to the charging connector and battery connectors (including the positive and negative battery connectors) being mounted at opposite ends of the housing along the first direction. The installation of the connectors does not increase the size of the housing in other directions (such as the second direction), thus reducing the space occupied by the housing in other directions. Furthermore, the positive relay, fuse, and positive battery connector are arranged side-by-side within the mounting cavity, while the negative relay and negative battery connector are spaced apart along the second direction on the same side as the positive relay. This avoids a cluttered arrangement of electrical components within the mounting cavity, ensuring a compact layout and further reducing the space occupied by the power distribution unit. Attached Figure Description

[0034] Various other advantages and benefits will become apparent to those skilled in the art upon reading the detailed description of the preferred embodiments below. The accompanying drawings are for illustrative purposes only and are not intended to limit the scope of this application. Furthermore, the same reference numerals denote the same parts throughout the drawings. In the drawings:

[0035] Figure 1 A structural diagram of a power distribution unit provided in an embodiment of this application.

[0036] Figure 2 for Figure 1 The diagram shows the structural structure of the power distribution unit enclosure.

[0037] Figure 3 for Figure 1 The diagram shows the structure of the power distribution unit behind the concealed enclosure.

[0038] Figure 4 for Figure 3 Top view of the structure shown;

[0039] Figure 5 for Figure 3 A structural diagram of the structure shown from another perspective;

[0040] Figure 6 for Figure 3 The structure shown is a structural diagram from another perspective.

[0041] Figure 7 for Figure 3 The structural diagram shown is from another perspective.

[0042] Figure 8 for Figure 1 The diagram shows the structure of the power distribution unit hidden behind the cover and enclosure.

[0043] Figure 9 for Figure 1 An exploded view of the power distribution unit shown.

[0044] Explanation of reference numerals in the attached figures:

[0045] 100. Power distribution unit; 10. Housing; 11. Bottom wall; 111. Base plate; 112. Mounting plate; 12. Side wall; 121. First wall; 122. Second wall; 123. Third wall; 124. Fourth wall; 13. Mounting cavity; 14. Flanged edge; 20. Charging connector; 21. Positive terminal; 22. Negative terminal; 30. Positive battery connector; 40. Negative battery connector; 50. Positive relay; 60. Fuse; 70. Direct current busbar; 80. Negative relay; 90. First current busbar; 91. First conductive section; 92. 110. Second conductive section; 120. Pre-charge relay; 130. Pre-charge resistor; 140. Communication connector; 150. Communication cable; 151. Positive high-voltage cable; 152. First part; 160. Second part; 170. Negative high-voltage cable; 180. Control line; 190. Acquisition line; 200. First cable; 210. Connector; 220. Wire harness clip; 230. Box cover; 240. Sealing ring; 250. Connector bracket; 260. Support column; 270. Fixing base; X, First direction; Y, Second direction; Z, Third direction. Detailed Implementation

[0046] To make the above-mentioned objectives, features, and advantages of this application more apparent and understandable, the specific embodiments of this application are described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of this application. However, this application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this application. Therefore, this application is not limited to the specific embodiments disclosed below.

[0047] In the description of this application, it should be understood that, where they appear, the terms “center,” “longitudinal,” “lateral,” “length,” “width,” “thickness,” “upper,” “lower,” “front,” “rear,” “left,” “right,” “vertical,” “horizontal,” “top,” “bottom,” “inner,” “outer,” “clockwise,” “counterclockwise,” “axial,” “radial,” and “circumferential” indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0048] Furthermore, where applicable, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0049] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "joining," "fixing," etc., shall be interpreted broadly. For example, they may refer to a fixed connection, a detachable connection, or an integral part; they may refer to a mechanical connection or an electrical connection; they may refer to a direct connection or an indirect connection through an intermediate medium; they may refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0050] In this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0051] It should be noted that, if an element is described as "fixed to" or "set on" another element, it can be directly on the other element or there may be an intervening element. When an element is described as "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only possible implementation.

[0052] See Figure 1 One embodiment of this application provides a power distribution unit 100 (PDU). The main functions of the power distribution unit 100 in the battery system include power distribution, circuit protection, and intelligent management.

[0053] See Figure 2The power distribution unit 100 includes a housing 10, which includes a bottom wall 11 and side walls 12. The side walls 12 are connected to the bottom wall 11 and together define a mounting cavity 13. Specifically, the mounting cavity 13 has an opening opposite to the bottom wall 11, allowing electrical components to be installed in the mounting cavity 13 through the opening. The side walls 12 have a first wall 121 and a second wall 122, which are arranged opposite to each other along a first direction X. In some embodiments, the housing 10 is a hollow cuboid structure, in which case the side walls 12 surround the bottom wall 11, and the first direction X can be either the length or width of the housing 10. It is conceivable that in other embodiments, the shape of the housing 10 is not limited, and the first direction X varies depending on the shape of the housing 10.

[0054] See Figure 3 The power distribution unit 100 also includes a charging connector 20, a positive battery connector 30, and a negative battery connector 40. The charging connector 20 is mounted on the first wall 121, while the positive battery connector 30 and negative battery connector 40 are both mounted on the second wall 122 and spaced apart along the second direction Y. The first direction X intersects the second direction Y. Specifically, the first direction X and the second direction Y are perpendicular. When the housing 10 is a hollow cuboid structure, one of the first direction X and the second direction Y is the length direction of the housing 10, and the other is the width direction of the housing 10.

[0055] See Figure 4 The power distribution unit 100 also includes electrical components such as a positive relay 50, a fuse 60, a direct current bus 70, a negative relay 80, and a first conductive bus 90. The positive relay 50, fuse 60, direct current bus 70, negative relay 80, and first conductive bus 90 are all installed in the mounting cavity 13 through openings. The positive terminal 21 of the charging connector 20, the positive relay 50, the direct current bus 70, and the positive battery connector 30 are sequentially electrically connected to form a first circuit. The negative terminal 22 of the charging connector 20, the negative relay 80, the first conductive bus 90, and the negative battery connector 40 are sequentially electrically connected to form a second circuit.

[0056] Positive battery connector 30 and negative battery connector 40 are used to connect the power battery for high-voltage output. Charging connector 20 is used to connect an external power source, allowing the external power source to charge the power battery through a first circuit and a second circuit. The first circuit and the second circuit constitute a charging circuit for the power battery. In some embodiments, the power distribution unit 100 is used to charge the power battery on the aircraft. Of course, in other embodiments, the power distribution unit 100 can also charge the power battery on other types of electrical devices, which is not limited here.

[0057] A relay is an electrical control device that causes a predetermined step change in the controlled quantity in the electrical output circuit when the change in the input quantity (excitation quantity) reaches a specified requirement. It has an interactive relationship between the control system (also known as the input circuit) and the controlled system (also known as the output circuit). It is commonly used in automated control circuits, and is essentially an "automatic switch" that uses a small current to control a large current. Therefore, it plays a role in automatic adjustment, safety protection, and circuit switching in the circuit. The positive relay 50 can control the on / off state of the first circuit, and the negative relay 80 can control the on / off state of the second circuit. A fuse 60 is an electrical device that breaks the circuit by melting its fusible element when the current exceeds a specified value. Fuses 60 are widely used in high and low voltage power distribution systems and electrical appliances as short-circuit and overcurrent protectors, and are one of the most commonly used protective devices. Fuses 60 can be used to control the on / off state of the circuit to protect connectors and other electrical components.

[0058] Further reading Figure 4 The positive relay 50, fuse 60, and positive battery connector 30 are aligned along the first direction X, with fuse 60 positioned between the positive relay 50 and positive battery connector 30 along the first direction X. Specifically, the positive relay 50, fuse 60, and positive battery connector 30 are arranged side-by-side in sequence. A direct conductive bus 70 extends along the first direction X, meaning the positive relay 50, direct conductive bus 70, fuse 60, and positive battery connector 30 are arranged side-by-side. The negative relay 80 and negative battery connector 40 are spaced apart along the second direction Y on the same side of the positive relay 50. Specifically, the negative relay 80, negative battery connector 40, and first conductive bus 90 are spaced apart along the second direction Y on the same side of the positive relay 50. The distance between the positive relay 50 and the negative relay 80 must meet safety creepage requirements.

[0059] The power distribution unit 100 provided in this embodiment has a charging connector 20 mounted on a first wall 121, and positive battery connector 30 and negative battery connector 40 both mounted on a second wall 122 and spaced apart along the second direction Y. This is equivalent to the charging connector 20 and battery connectors (including positive battery connector 30 and negative battery connector 40) being mounted at opposite ends of the housing 10 along the first direction X. The installation of the connectors does not increase the size of the housing 10 in other directions (such as the second direction Y), thus reducing the space occupied by the housing 10 in other directions. Furthermore, the positive relay 50, fuse 60, and positive battery connector 30 are arranged side-by-side within the mounting cavity 13, while the negative relay 80 and negative battery connector 40 are spaced apart along the second direction Y on the same side as the positive relay 50. This avoids a cluttered arrangement of electrical components in the mounting cavity 13, ensuring a compact layout of the electrical components within the mounting cavity 13, further reducing the space occupied by the power distribution unit 100, facilitating installation, and improving installation convenience.

[0060] In some embodiments, see Figure 2 and Figure 3 The bottom wall 11 includes a bottom plate 111 and a mounting plate 112. The side wall 12 is connected to the bottom plate 111. The mounting plate 112 is located on the side of the bottom plate 111 facing the opening. Both the positive relay 50 and the negative relay 80 are mounted on the mounting plate 112 to improve the sealing of the housing 10. To ensure the connection between the mounting plate 112 and the bottom plate 111, a fixing bracket is provided on the bottom plate 111. Nuts are pre-embedded in the fixing bracket, and fixing screws pass through the mounting plate 112 and are connected to the nuts pre-embedded in the fixing bracket to achieve a fixed connection between the mounting plate 112 and the bottom plate 111. It can be understood that in some embodiments, the bottom wall 11 can also be set in other ways, such as omitting the mounting plate 112, in which case the positive relay 50 and the negative relay 80 are directly mounted on the bottom plate 111.

[0061] In some embodiments, see Figure 5 The power distribution unit 100 also includes a support column 250 mounted on the mounting plate 112. The support column 250 extends along a third direction Z. One end of the fuse 60 is connected to the end of the support column 250 along the third direction Z away from the mounting plate 112, and the other end is connected to the positive battery connector 30. One end of the direct current bus 70 is connected to the end of the positive relay 50 along the third direction Z away from the mounting plate 112, and the other end is connected to the end of the support column 250 along the third direction Z away from the mounting plate 112, and is electrically connected to the fuse 60. The support column 250 serves to support the direct current bus 70 and the fuse 60, facilitating their installation. At this time, the direct current bus 70 and the fuse 60 are suspended above the bottom wall 11, facilitating the connection of the fuse 60 to the positive battery connector 30.

[0062] In this configuration, the first direction X, the second direction Y, and the third direction Z intersect each other. Specifically, the first direction X, the second direction Y, and the third direction Z are perpendicular to each other. In some specific embodiments, when the housing 10 is a hollow cuboid structure, the third direction Z is the height direction of the housing 10.

[0063] In some embodiments, the negative relay 80 is opposite to the support post 250 along the second direction Y, thus preventing the negative relay 80 from exceeding the range covered by the positive relay 50 and the fuse 60 along the first direction X, thereby improving the compactness of the power distribution unit 100 layout.

[0064] In some embodiments, see Figure 6 and Figure 7 The power distribution unit 100 also includes a positive high-voltage cable 150 and a negative high-voltage cable 160 disposed within the mounting cavity 13. The positive high-voltage cable 150 connects the positive terminal 21 and the positive relay 50, and the negative high-voltage cable 160 connects the negative terminal 22 and the negative relay 80. By providing the positive high-voltage cable 150 and the negative high-voltage cable 160, it is convenient to connect the positive terminal 21 to the positive relay 50 and to connect the negative terminal 22 to the negative relay 80.

[0065] For details, please refer to [link / reference]. Figure 4 The positive relay 50 is offset from the charging connector 20 along the first direction X. At this time, the direct current bus 70, support post 250, fuse 60, and positive battery connector 30 are also offset from the charging connector 20 along the first direction X. The positive high-voltage cable 150 includes a first part 151 and a second part 152 connected to each other. The first part 151 is connected to the positive terminal 21 and extends along the first direction X. The second part 152 is bent away from the negative relay 80 relative to the first part 151 to connect to the positive relay 50. By setting the positive high-voltage cable 150 to a bent structure, a safe creepage distance is ensured between the positive relay 50 and the negative relay 80, resulting in a compact structure of the electrical components within the mounting cavity 13.

[0066] Further reading Figure 4 The negative relay 80 is positioned opposite the charging connector 20 along the first direction X, and the negative high-voltage cable 160 extends along the first direction X to connect the negative terminal 22 and the negative relay 80. In this way, while ensuring a safe creepage distance between the positive relay 50 and the negative relay 80, the spacing between the positive relay 50 and the negative relay 80 in the second direction Y is further reduced, improving structural compactness.

[0067] In some embodiments, see further reference. Figure 4The first conductive busbar 90 includes a first conductive segment 91 and a second conductive segment 92 connected to each other. The first conductive segment 91 is electrically connected to the negative relay 80 and extends along the second direction Y close to the positive relay 50. The second conductive segment 92 extends along the first direction X to be electrically connected to the negative battery connector 40. This arrangement ensures that the negative battery connector 40 is positioned as close as possible to the positive battery connector 30 in the second direction Y, and that the second wall 122, located on the side of the negative battery connector 40 away from the positive battery connector 30, provides sufficient space for installing other components.

[0068] Specifically, the first conductive segment 92 is connected to the end of the negative relay 80 away from the bottom wall 11, which allows the first conductive bus 90 to be suspended above the bottom wall 11. This not only facilitates the connection between the first conductive bus 90 and the negative battery connector 40, but also increases the distance between the first conductive bus 40 and other components installed on the bottom wall 11, reducing mutual interference.

[0069] In some embodiments, see further reference. Figure 4 The power distribution unit 100 also includes a pre-charge relay 110 and a pre-charge resistor 120 mounted on a mounting plate 112. The pre-charge relay 110 and the pre-charge resistor 120 are opposite each other along a first direction X, and are located between the positive relay 50 and the negative relay 80 along a second direction Y. The pre-charge relay 110 and the pre-charge resistor 120 are connected in series, and are electrically connected to both ends of the positive relay 50. That is, the pre-charge relay 110 and the pre-charge resistor 120 are connected in series to form a pre-charge circuit, and the two ends of the pre-charge circuit are electrically connected to the two ends of the positive relay 50 through cables. That is, the pre-charge circuit is connected in parallel with the positive relay 50.

[0070] The main function of the precharge relay 110 is to limit the initial current and protect circuit components from high current surges by controlling the on / off state of the precharge circuit when the high-voltage system is powered on or charged. The core function of the precharge resistor 120 is to limit the instantaneous current when the high-voltage circuit is powered on, protecting electronic components from damage caused by current surges.

[0071] The precharge relay 110 and precharge resistor 120 are arranged side by side, which not only saves space but also facilitates the installation of the wiring harness connecting the precharge relay 110 and precharge resistor 120 as well as the wiring harness connecting the precharge circuit and the positive relay 50. Furthermore, the precharge relay 110 and precharge resistor 120 are arranged along the second direction Y between the positive relay 50 and the negative relay 80, making the spatial layout of each electrical component more compact and further reducing the footprint of the power distribution unit 100.

[0072] Optionally, the pre-charge relay 110 is located between the charging connector 20 and the pre-charge resistor 120 along the first direction X, and the pre-charge resistor 120 is located between the negative relay 80 and the support post 250 along the second direction Y. Of course, in some other embodiments, the pre-charge resistor 120 may also be located between the charging connector 20 and the pre-charge relay 110 along the first direction X, and the pre-charge relay 110 may be located between the negative relay 80 and the support post 250 along the second direction Y; this is not limited here.

[0073] In some embodiments, see further reference. Figure 3 and Figure 5 The power distribution unit 100 also includes a communication connector 130, which is mounted on the second wall 122. Specifically, the communication connector 130, the positive battery connector 30, and the negative battery connector 40 are all mounted on the second wall 122. The negative battery connector 40 is located between the communication connector 130 and the positive battery connector 30 along the second direction Y. The charging connector 20 is electrically connected to the communication connector 130 via a communication cable 140.

[0074] A communication cable 140 connects the charging connector 20 and the communication connector 130 to transmit signals. The communication connector 130 is used to connect cables, harnesses, etc., to the battery control module to feed back low-voltage signals to the battery control module for managing the charging of the power battery. In some embodiments, the power battery is not removed from the electrical device during charging, but is charged directly on the electrical device. For example, when the electrical device is an aircraft, the communication connector 130 feeds back signals to the battery control module, the battery control module feeds back signals to the aircraft control module, the aircraft control module adjusts the information and then sends it to the battery control module, thereby controlling the opening and closing of the control relay to control the input and stop of current to the power battery. In other embodiments, the power battery can also be removed from the electrical device for charging, which is not limited here.

[0075] Optionally, see Figure 8 One end of the communication cable 140 connected to the charging connector 20 is spaced apart from the positive high-voltage cable 150 and the negative high-voltage cable 160 along the third direction Z. Specifically, the positive high-voltage cable 150 and the negative high-voltage cable 160 are at the same height in the third direction Z. The communication cable 140 is divided into two routes: one route is located above the positive high-voltage cable 150 and the negative high-voltage cable 160 along the third direction Z, and the other route is located below the positive high-voltage cable 150 and the negative high-voltage cable 160 along the third direction Z. In this way, the communication cable 140 can avoid the high-voltage cables to prevent mutual interference between the communication cable 140 and the high-voltage cables.

[0076] In some embodiments, see Figures 5-7The power distribution unit 100 includes a control line 170 and a data acquisition line 180 disposed within the mounting cavity 13. Both the positive relay 50 and the negative relay 80 are connected to the communication connector 130 via the control line 170 and the data acquisition line 180. The power distribution unit 100 also includes a first cable 190 disposed within the mounting cavity 13. The communication cable 140, control line 170, and data acquisition line 180 are all connected to the communication connector 130 via the first cable 190. Thus, the battery control system can control the opening and closing of the positive relay 50 and the negative relay 80 via the corresponding control line 170, thereby controlling whether the power battery is being charged. The battery control system can acquire the current signal flowing through the positive relay 50 and the negative relay 80 via the corresponding data acquisition line 180, facilitating better control of the first and second circuits.

[0077] The precharge relay 110 is also connected to the first cable 190 via the control line 170, and the battery control module can also control the opening and closing of the precharge relay 110 via the control line 170 connected to the precharge relay 110.

[0078] In some embodiments, see Figure 3 The communication cable 140, the control line 170 and the acquisition line 180 connected to the positive relay 50, and the control line 170 connected to the pre-charge relay 110 converge at the connector 200 and are connected to the first cable 190 through the connector 200. The control line 170 and the acquisition line 180 connected to the negative relay 80 are directly connected to the first cable 190. In this way, the first cable 190 is installed directly from the side closest to the communication connector 130, while the communication cable 140, the control line 170 and the acquisition line 180 connected to the positive relay 50, and the control line 170 connected to the pre-charge relay 110 are installed from the other side, and finally connected through the connector 200. This facilitates installation, improves installation efficiency, reduces the length of the control and acquisition lines, and eliminates the need for multiple control and acquisition lines to be individually connected to the communication connector, thus improving installation efficiency.

[0079] Continue reading Figure 5 Since the negative relay 80 is located closer to the communication connector 130 than the positive relay 50 and the precharge relay 110, the control line 170 and the acquisition line 180 connected to the negative relay 80 can be directly connected to the first cable 190 without going through the connector 200, so as to reduce the diameter of the first cable 190 and avoid the first cable 190 being too thick, inflexible, and difficult to bend and adjust.

[0080] In some embodiments, see further reference. Figure 2 and Figure 5The side wall 12 also includes a third wall 123 and a fourth wall 124 disposed opposite each other along a third direction Z. The third wall 123 is disposed closer to the negative relay 80 relative to the fourth wall 124. The first wall 121, the third wall 123, the second wall 122, and the fourth wall 124 are connected in sequence and together with the bottom wall 11 define a mounting cavity 13. The power distribution unit 100 also includes a wire harness clip 210 and a connector bracket 240 mounted on the third wall 123. The two wire harness clips 210 are disposed on both sides of the connector bracket 240 along a first direction X. The connector 200 is constrained to the third wall 123 by the connector bracket 240. The communication cable 140 (partially or entirely) is constrained to one side of the connector 200 by the wire harness clip 210, and the first cable 190 is constrained to the other side of the connector 200 by the other wire harness clip 210. In this way, the communication cable 140, the acquisition line 180, and the control line 170 are all constrained on the third wall 123, ensuring the neatness of the wiring. At the same time, the way the low-voltage wiring harness (including the communication cable 140, the acquisition line 180, and the control line 170) is routed on the third wall 123 will not occupy too much space in the mounting cavity 13, which helps to reduce the footprint of the power distribution unit 100. Furthermore, it prevents the low-voltage wiring harness (including the communication cable 140, the acquisition line 180, and the control line 170) from passing between high-voltage cables, so as to avoid the high voltage affecting the communication current of the low-voltage wiring harness.

[0081] In some embodiments, see Figure 9 The power distribution unit 100 also includes a cover 220. The side wall 12 of the enclosure 10 forms a flange 14 at the end away from the bottom wall 11 along the third direction Z. A sealing gasket is sealed between the flange 14 and the cover 220. The cover 220 and the enclosure 10 form a sealed space to protect the electrical components in the mounting cavity 13.

[0082] Furthermore, the power distribution unit 100 also includes a mounting base 260, which is connected to the outer side of the side wall 12. When charging the power battery, the power distribution unit 100 is externally positioned outside the power battery. The mounting base 260 keeps the power distribution unit 100 relatively fixed to the external power source, thereby ensuring the connection stability between the charging connector 20 and the external power source and guaranteeing the charging effect. It is evident that the power distribution unit 100 in this application does not need to be mounted on the electrical device, which can reduce the mass of the electrical device (such as an aircraft) and increase energy density.

[0083] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0084] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of this patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A power distribution unit, characterized by, include: The housing (10) includes a bottom wall (11) and a side wall (12) that together define a mounting cavity (13), the side wall (12) having a first wall (121) and a second wall (122) disposed opposite to each other along a first direction (X); A charging connector (20) installed on the first wall (121), a positive battery connector (30) and a negative battery connector (40) installed on the second wall (122) and arranged sequentially along the second direction (Y) intersecting the first direction (X); The positive relay (50), fuse (60), direct conduction bus (70), negative relay (80) and first conduction bus (90) are all installed in the mounting cavity (13); The positive relay (50), the fuse (60), and the positive battery connector (30) are aligned along the first direction (X). The positive terminal (21) of the charging connector (20), the positive relay (50), the direct current bus (70), the fuse (60), and the positive battery connector (30) are sequentially electrically connected. The negative relay (80) and the negative battery connector (40) are spaced apart along the second direction (Y) on the same side of the positive relay (50). The negative terminal (22) of the charging connector (20), the negative relay (80), the first current bus (90), and the negative battery connector (40) are sequentially electrically connected.

2. The power distribution unit of claim 1, wherein, The first conductive bus (90) includes a first conductive segment (91) and a second conductive segment (92) that are electrically connected to each other; The first conductive segment (91) is electrically connected to the negative relay (80) and extends along the second direction (Y) close to the positive relay (50), and the second conductive segment (92) extends along the first direction (X) to be electrically connected to the negative battery connector (40).

3. The power distribution unit of claim 1, wherein, The power distribution unit further includes a pre-charge relay (110) and a pre-charge resistor (120) installed in the mounting cavity (13). The pre-charge relay (110) and the pre-charge resistor (120) are opposite each other along the first direction (X) and are located between the negative relay (80) and the positive relay (50) along the second direction (Y). The precharge relay (110) and the precharge resistor (120) are connected in series, and both are electrically connected to the two ends of the positive relay (50).

4. The power distribution unit of claim 3, wherein, The positive relay (50), the negative relay (80), the precharge relay (110), and the precharge resistor (120) are all mounted on the bottom wall (11); The direct-drive busbar (70), the fuse (60) and the first busbar (90) are suspended above the bottom wall (11) along a third direction (Z); The first direction (X), the second direction (Y), and the third direction (Z) intersect each other.

5. The power distribution unit of claim 1, wherein, The power distribution unit also includes a communication connector (130) mounted on the second wall (122), and the negative battery connector (40) is located between the communication connector (130) and the positive battery connector (30) along the second direction (Y); The charging connector (20) and the communication connector (130) are electrically connected via a communication cable (140).

6. The power distribution unit of claim 5, wherein, The power distribution unit includes a positive high-voltage cable (150) and a negative high-voltage cable (160); The positive high-voltage cable (150) connects the positive terminal (21) and the positive relay (50), and the negative high-voltage cable (160) connects the negative terminal (22) and the negative relay (80); One end of the communication cable (140) connected to the charging connector (20) is spaced apart from the positive high-voltage cable (150) and the negative high-voltage cable (160) along the third direction (Z); The first direction (X), the second direction (Y), and the third direction (Z) intersect each other.

7. The power distribution unit of claim 6, wherein, The positive relay (50) is offset from the charging connector (20) along the first direction (X). The positive high-voltage cable (150) includes a first part (151) and a second part (152) that are connected to each other. The first part (151) is connected to the positive terminal (21) and extends along the first direction (X). The second part (152) is deflected away from the negative relay (80) relative to the first part (151) to be connected to the positive relay (50). The negative relay (80) is opposite the charging connector (20) along the first direction (X), and the negative high-voltage cable (160) extends along the first direction (X) to connect the negative terminal (22) and the negative relay (80).

8. The power distribution unit of claim 5, wherein, The power distribution unit also includes a control line (170) and a data acquisition line (180). The positive relay (50) and the negative relay (80) are both connected to the communication connector (130) through the control line (170) and the data acquisition line (180). The power distribution unit also includes a first cable (190), and the communication cable (140), the control line (170) and the acquisition line (180) are connected to the communication connector (130) through the first cable (190).

9. The power distribution unit of claim 8, wherein, The communication cable (140), the control line (170) connected to the positive relay (50), and the acquisition line (180) converge at the connector (200) and are connected to the first cable (190) through the connector (200); The control line (170) and the acquisition line (180) connected to the negative relay (80) are directly connected to the first cable (190).

10. The power distribution unit according to claim 9, characterized in that, The sidewall (12) includes a third wall (123) and a fourth wall (124) disposed opposite each other along a third direction (Z), wherein the third wall (123) is disposed close to the negative relay (80) relative to the fourth wall (124); The first wall (121), the third wall (123), the second wall (122) and the fourth wall (124) are connected in sequence, and the first direction (X), the second direction (Y) and the third direction (Z) intersect each other; The power distribution unit includes a wire harness clip (210) and a connector bracket (240) disposed on the inner side of the third wall (123). Two wire harness clips (210) are disposed on both sides of the connector bracket (240) along a first direction (X). The connector (200) is constrained by the connector bracket (240). The communication cable (140) is constrained to one side of the connector (200) by the wire harness clip (210). The first cable (190) is constrained to the other side of the connector (200) by the other wire harness clip (210).

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