A distributed BDU structure and battery pack

Abstract

This utility model discloses a distributed BDU structure and battery pack, including a BDU base, structural mounting components, a BMS, battery modules, high-voltage electrical functional components, and copper busbars. The BDU base serves as the mounting substrate. The structural mounting components include a fuse box, a shunt bracket, and a BMS bracket. The high-voltage electrical functional components include a main positive contactor, a main negative contactor, a pre-charge contactor, a pre-charge resistor, and a shunt, all fixed to the BDU base. The high-voltage electrical functional components form a circuit with the battery modules via the copper busbars and work in conjunction with the BMS to achieve battery pack charging and discharging control, circuit overload protection, high-voltage data acquisition, and low-voltage control. This utility model achieves advantages such as short development cycle, low cost, full space utilization, high flexibility, and a series circuit scheme by fixing the high-voltage electrical functional components and structural mounting components to the BDU base and working in conjunction with the BMS to achieve battery pack charging and discharging control through a distributed integrated scheme.

Description

Technical Field

[0001] This utility model relates to the field of electric vehicle technology, and in particular to a distributed BDU structure and battery pack. Background Technology

[0002] Currently, electric vehicles represent the future trend of automotive development, and the performance of their battery packs is crucial. The BDU (Battery Distribution Unit), as a core component, is responsible for managing and coordinating the electrical performance of the battery pack. Existing BDU designs mostly adopt an integrated approach, placing various electrical components within a complex plastic housing. While this design provides comprehensive battery management functions, it also introduces several problems. First, the complex housing design leads to longer development cycles, higher mold costs, and a correspondingly longer verification period. Second, the use of multiple materials increases costs. Furthermore, the relatively fixed layout of this integrated approach results in poor heat dissipation, further limiting the overall performance of the battery pack.

[0003] Some attempts have emerged in the market to simplify BDU design, such as eliminating the BDU cover to reduce costs. However, this approach has limited cost-saving effects and is unlikely to significantly reduce design complexity. Furthermore, these integrated BDU solutions typically still rely on BDU suppliers for support, increasing the complexity of supply chain management for OEMs.

[0004] In summary, the current BDU solution has many shortcomings and urgently needs a new design approach that can reduce design difficulty and development cycle, reduce mold opening and material types, significantly reduce costs, optimize heat dissipation performance, improve layout flexibility, and enable battery pack manufacturers to assemble it themselves. Utility Model Content

[0005] The purpose of this utility model is to overcome the shortcomings of the existing technology. In order to achieve the above purpose, a distributed BDU structure and battery pack are adopted to solve the problems mentioned in the background technology.

[0006] A distributed BDU structure includes a BDU base, structural mounting components, a BMS, a battery module, high-voltage electrical functional components, and copper busbars;

[0007] The BDU base serves as the mounting base;

[0008] The structural mounting components include a fuse box, a shunt bracket, and a BMS bracket;

[0009] The high-voltage electrical functional components include a main positive contactor, a main negative contactor, a pre-charge contactor, a pre-charge resistor, and a shunt, which are fixed on the BDU base.

[0010] The high-voltage electrical functional components form a circuit with the battery module through copper busbars, and work in conjunction with the BMS to realize battery pack charging and discharging control, circuit overload protection, high-voltage acquisition, and low-voltage control.

[0011] As a further aspect of this utility model: the BDU base is a metal plate with flanges at both ends along its length, the flanges facing upwards or downwards to increase the structural strength of the metal plate; and through holes at both ends along its width for fixing the BDU base to the battery pack beam or bracket with bolts. The metal plate BDU base has high strength and rigidity, providing stable and reliable support for the BDU. The flanges at both ends can face upwards or downwards according to actual installation requirements, increasing installation flexibility. The through holes at both ends along the width facilitate the use of bolts to firmly fix the BDU base to the battery pack beam or bracket, ensuring the stability of the entire battery system.

[0012] As a further aspect of this invention: the BDU base is provided with a press-fit nut, and the high-voltage electrical functional components are bolted to the press-fit nut. The press-fit nut has good fixing performance, which can firmly lock the high-voltage electrical functional components to the BDU base, preventing them from loosening due to vibration during vehicle operation, thereby improving the reliability of the connection. This connection method is not only easy to install, but can also withstand greater tensile and torsional forces, extending the service life of the components.

[0013] As a further aspect of this invention, a U-shaped bracket is welded onto the BDU base. The welding of the U-shaped bracket provides additional mounting positions and support for certain special components, enhancing the functionality and structural stability of the BDU base. Its shape better adapts to the installation requirements of certain components, improving space utilization.

[0014] As a further embodiment of this invention: the BMS bracket is a plastic component with metal inserts, its body having staggered reinforcing ribs and bushinged bosses on both sides; two BMS brackets are assembled facing each other, and the BMS is fixed to the bushings of the two sets of bosses by bolts. The plastic BMS bracket with metal inserts combines the lightweight of plastic with the strength of metal, and the staggered reinforcing ribs further improve the rigidity of the bracket, enabling it to better support the weight of the BMS and resist vibration and impact. The bushinged bosses on both sides provide a precise installation position for the BMS, and the facing assembly method also ensures the stability of the BMS and the reliability of the connection.

[0015] As a further aspect of this invention: the BDU base has a clearance groove in the BMS installation area, the BMS bracket is fixed to the upper surface of the BDU base, and the BMS is suspended in the area above and below the clearance groove. The clearance groove design allows the BMS portion to be placed below the BDU base, effectively reducing the height space occupied by the BMS in the PACK system and improving the feasibility of the PACK system solution.

[0016] As a further aspect of this utility model: the fuse box includes a fuse base and a removable top cover. The fuse base is fixed to the BDU base, and the fuse is installed inside the fuse base and sealed by the top cover. The base has good insulation performance, ensuring the safe operation of the fuse. The removable top cover facilitates the inspection and replacement of the fuse without disassembling the entire fuse box, improving the convenience and efficiency of maintenance. Installing the fuse inside the fuse base fixed to the BDU base helps protect the fuse from damage by external factors.

[0017] As a further embodiment of this utility model: the pre-charge resistor is fixed to the BDU base by a metal bracket.

[0018] The metal bracket provides robust support and excellent heat dissipation for the pre-charge resistor, ensuring its stable operation during operation.

[0019] As a further embodiment of this utility model: the main positive contactor, the main negative contactor, and the precharge contactor are directly fixed to the BDU base;

[0020] The splitter is mounted on the BDU base via two T-shaped splitter brackets, and the contact surface between the splitter brackets and the BDU base is provided with a positioning pin structure.

[0021] The main positive contactor, main negative contactor, and precharge contactor are directly fixed to the BDU base, simplifying the installation structure, reducing installation costs, and facilitating electrical connections and maintenance. The shunt is mounted via two T-shaped shunt brackets, improving its installation stability, while the locating pin structure ensures precise positioning between the shunt brackets and the BDU base, guaranteeing accurate electrical connections between the shunt and other components, and improving the overall battery system performance and reliability.

[0022] The second aspect of the technical solution: a battery pack that adopts a distributed BDU structure as described in any of the above.

[0023] Compared with the prior art, the present invention has the following technical advantages:

[0024] The above technical solution, by setting up a BDU base and mounting a fuse box, shunt bracket, BMS bracket, main positive / negative contactor, pre-charge contactor, pre-charge resistor, shunt, and copper busbar on it; and through the BMS's coordinated control of the contactors, fuse box, and shunt, achieves battery pack charge / discharge management, circuit overload protection, high-voltage acquisition, and low-voltage control functions. This significantly saves space and weight, while the rigid connection enhances structural stability and vibration resistance, achieving highly reliable charge / discharge control and circuit protection. Attached Figure Description

[0025] The specific embodiments of this utility model will now be described in detail with reference to the accompanying drawings:

[0026] Figure 1 This is a front view schematic diagram of a distributed BDU structure according to an embodiment of this application.

[0027] Figure 2 This is a schematic diagram of a distributed BDU structure according to an embodiment of this application;

[0028] Figure 3 This is a front view schematic diagram of the BDU base according to an embodiment of this application;

[0029] Figure 4 This is a bottom view of the BDU base according to an embodiment of this application;

[0030] Figure 5 This is a front view schematic diagram of a BMS bracket according to an embodiment of this application;

[0031] Figure 6 This is a left-side view of a BMS bracket according to an embodiment of this application.

[0032] Figure 7 This is a schematic diagram of the fit between the fuse and the fuse box according to an embodiment of this application;

[0033] Figure 8 This is a schematic diagram of the pre-charge resistor and resistor bracket in an embodiment of this application;

[0034] Figure 9 This is a schematic diagram of the coupling between the splitter and the splitter bracket according to an embodiment of this application.

[0035] In the diagram: 1. BDU base; 2. Second copper busbar; 3. Wiring harness; 4. Fuse box; 5. Pre-charge resistor; 6. First copper busbar; 7. Module; 8. Module positive terminal; 9. Module negative terminal; 10. Connector; 11. Third copper busbar; 12. Sixth copper busbar; 13. Fourth copper busbar; 14. Fifth copper busbar; 15. BMS; 16. BMS bracket; 17. Battery pack beam; 18. Pre-charge contactor; 19. Wire 20. Main positive contactor; 21. Main negative contactor; 22. Shunt; 23. Shunt bracket; 24. Flanged edge; 25. Through hole for fixing cable ties; 26. Through hole; 27. Clearance groove; 28. U-shaped bracket; 29. ​​Press-fit nut; 30. Boss; 31. Staggered reinforcing rib; 32. Insert; 33. Bushing; 34. Resistor bracket; 35. Top cover; 36. Fuse; 37. Fuse base. Detailed Implementation

[0036] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0037] Please refer to Figure 1 and Figure 2 In this embodiment of the utility model, a distributed BDU structure includes a BDU base 1, a fuse box 4, a shunt bracket 23, a BMS 15, a BMS bracket 16, a wire harness 3, a module 7, a main positive contactor 20, a main negative contactor 21, a precharge contactor 18, a precharge resistor 5, a shunt 22, a copper busbar, and a connector 10, etc.

[0038] BDU base 1 serves as the mounting base;

[0039] like Figure 3 As shown, the diagram is a front view schematic of the BDU base;

[0040] like Figure 4 As shown, the diagram is a bottom view of the BDU base;

[0041] The structural mounting components include fuse box 4, shunt 22 bracket, and BMS bracket 16;

[0042] The high-voltage electrical functional components include a main positive contactor 20, a main negative contactor 21, a pre-charge contactor 18, a pre-charge resistor 5, and a shunt 22, which are fixed on the BDU base 1.

[0043] Among them, the high-voltage electrical functional components form a circuit with the battery module 7 through the copper busbar, and work with the BMS15 to realize battery pack charging and discharging control, circuit overload protection, high voltage acquisition, and low voltage control.

[0044] In this embodiment, the BDU base 1 is a metal plate with flanges 24 at both ends in the length direction. The flanges 24 are oriented upwards or downwards to increase the structural strength of the metal plate. Through holes 26 are provided at both ends in the width direction to fix the BDU base 1 to the battery pack beam 17 or the bracket with bolts.

[0045] Specifically, the BDU base 1 is made of steel plate or aluminum plate. Steel plate has high strength and heavy weight, while aluminum plate has low strength and light weight. The choice is made according to the actual project requirements. The BDU base has flanges 24 at both ends in the X direction (length direction) to increase strength. The flanges can be up or down. The BDU base has through holes 26 at both ends in the Y direction (width direction). The BDU base is fixed to the battery pack beam 17 or bracket by bolts.

[0046] In this embodiment, the BDU base 1 is provided with a press-fit nut 29, and the high-voltage electrical functional components are bolted to the press-fit nut 29.

[0047] The BDU base 1 is equipped with a rivet nut 29 for fixing various parts. The BDU base is provided with a through hole 25 for fixing the wire harness clip 19, and a part of the wire harness 3 is fixed to the wire harness clip 19.

[0048] In this embodiment, a U-shaped bracket 28 is welded onto the BDU base 1.

[0049] The BDU base 1 is welded with a U-shaped bracket 28. The U-shaped bracket 28 is made of steel or aluminum, depending on the actual project requirements. The bracket 28 has through holes for fixing the wire harness clips. The wire harness 3 is fixed to the wire harness clips.

[0050] In this embodiment, as Figure 5 As shown, the diagram is a front view schematic of the BMS bracket;

[0051] like Figure 6 As shown, the diagram is a schematic diagram of the BMS bracket from the left.

[0052] BMS bracket 16 is a plastic part with metal insert 32. Its body is provided with staggered reinforcing ribs 31 and bosses 30 with bushings 33 on both sides. Two BMS brackets 16 are assembled in opposite directions, and BMS 15 is fixed in the bushings 33 of the two sets of bosses 30 by bolts.

[0053] The BMS bracket 16 is made of plastic, which is lightweight and low-cost. It has an insert 32 with internal threads. The BMS bracket 16 has staggered reinforcing ribs 31 to increase strength. It has a boss 30 on the side with a bushing 33 inside. The bushing 33 has a hole for light. Two BMS brackets 16 can be used together to fix BMS 15 at both ends.

[0054] In this embodiment, the BDU base 1 is provided with a clearance groove 27 in the BMS15 installation area, the BMS bracket 16 is fixed to the upper surface of the BDU base 1, and the BMS15 is suspended in the upper and lower areas of the clearance groove 27.

[0055] The BDU base 1 has a clearance groove 27 in the BMS area to allow BMS 15 to pass. BMS 15 is fixed on BMS bracket 16, and BMS bracket 16 is fixed to BDU base 1 by bolts.

[0056] like Figure 7 As shown, the diagram illustrates the connection between the fuse and the fuse box.

[0057] In this embodiment, the fuse box 4 includes a fuse base 37 and a detachable top cover 35. The fuse base 37 is fixed on the BDU base 1, and the fuse 36 is installed inside the fuse base 37 and encapsulated by the top cover 35.

[0058] The fuse box 4 is made of plastic, which is lightweight, low-cost, and has good insulation. The fuse base 37 is fixed on the BDU base 1, the fuse 36 is fixed on the fuse base 37, and the fuse cover 35 is fixed on the fuse base 37.

[0059] In this embodiment, as Figure 8 As shown in the figure, the diagram illustrates the cooperation between the pre-charge resistor 5 and the resistor bracket; the pre-charge resistor 5 is fixed to the BDU base 1 by a metal bracket.

[0060] The metal bracket provides solid support and good heat dissipation for the pre-charge resistor 5, ensuring stable operation of the pre-charge resistor 5 during operation.

[0061] The pre-charge resistor 5 is equipped with a resistor bracket 34, which is made of steel or aluminum plate and is fixed to the BDU base 1.

[0062] In this embodiment, the main positive contactor 20, the main negative contactor 21, and the precharge contactor 18 are directly fixed to the BDU base 1;

[0063] like Figure 9 As shown in the figure, the diagram illustrates the connection between the splitter and the splitter bracket.

[0064] The splitter 22 is mounted on the BDU base 1 via two T-shaped splitter 22 brackets, and the contact surface between the splitter 22 bracket and the BDU base 1 is provided with a positioning pin structure.

[0065] The main positive contactor 20, the main negative contactor 21, and the precharge contactor 18 are fixed on the BDU base 1. The shunt bracket 23 is a plastic part with a T-shape. The shunt 22 is fixed on the two shunt brackets 23, and the shunt brackets 23 are fixed on the BDU base 1.

[0066] The first copper busbar 6 connects the module's main positive terminal 8 and the fuse 36; the second copper busbar 2 connects the fuse 36 and the main positive contactor 20; the third copper busbar 11 connects the main positive contactor 20 and the connector 10; the fourth copper busbar 13 connects the module's main negative terminal 9 and the shunt 22; the fifth copper busbar 14 connects the shunt 22 and the main negative contactor 21; and the sixth copper busbar 12 connects the main negative contactor 21 and the connector 10, forming a circuit between the various components.

[0067] The second aspect of the technical solution: a battery pack that adopts a distributed BDU structure as described in any of the above.

[0068] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within this invention, and no reference numerals in the claims should be construed as limiting the scope of the claims.

[0069] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A distributed BDU architecture, characterized by, Includes BDU base (1), structural mounting components, BMS (15), battery module (7), high-voltage electrical functional components, and copper busbar; The BDU base (1) serves as the mounting base; The structural mounting components include a fuse box (4), a shunt bracket (23), and a BMS bracket (16); The high-voltage electrical functional components include a main positive contactor (20), a main negative contactor (21), a pre-charge contactor (18), a pre-charge resistor (5), and a shunt (22), which are fixed on the BDU base (1). The high-voltage electrical functional components form a circuit with the battery module (7) through copper busbars, and work with the BMS (15) to realize battery pack charging and discharging control, circuit overload protection, high voltage acquisition, and low voltage control.

2. The distributed BDU structure of claim 1, wherein, The BDU base (1) is a metal plate with flanges (24) at both ends in the length direction. The flanges (24) are oriented upwards or downwards to increase the structural strength of the metal plate. Through holes (26) are provided at both ends in the width direction to fix the BDU base (1) to the battery pack beam (17) or bracket by bolts.

3. The distributed BDU structure of claim 2, wherein, The BDU base (1) is provided with a press-fit nut (29), and the high-voltage electrical functional components are bolted to the press-fit nut (29).

4. The distributed BDU structure of claim 3, wherein, A U-shaped bracket (28) is welded onto the BDU base (1).

5. The distributed BDU structure of claim 1, wherein, The BMS (15) bracket is a plastic part with a metal insert (32). Its body is provided with insert (32) and the two sides are provided with bosses (30) with bushings (33). The two BMS (15) brackets are assembled in opposite directions, and the BMS (15) is fixed in the bushings (33) of the two sets of bosses (30) by bolts.

6. The distributed BDU structure of claim 5, wherein, The BDU base (1) has a clearance groove (27) in the BMS (15) installation area. The BMS bracket (16) is fixed on the upper surface of the BDU base (1), and the BMS (15) is suspended in the area above and below the clearance groove (27).

7. The distributed BDU structure of claim 1, wherein, The fuse box (4) includes a fuse base (37) and a removable top cover (35). The fuse (36) base is fixed on the BDU base (1), and the fuse (36) is installed in the fuse base (37) and sealed by the top cover.

8. The distributed BDU structure of claim 1, wherein, The pre-charge resistor (5) is fixed to the BDU base (1) by a metal bracket.

9. The distributed BDU structure of claim 1, wherein, The main positive contactor (20), the main negative contactor (21), and the precharge contactor (18) are directly fixed to the BDU base (1); The splitter (22) is mounted on the BDU base (1) by two T-shaped splitter brackets, and the contact surface between the splitter bracket (23) and the BDU base (1) is provided with a positioning pin structure.

10. A battery pack, characterized by, The distributed BDU structure as described in any one of claims 1 to 9 is adopted.

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