A high-voltage plug-in grounding structure for an integrated controller and its controller.

Abstract

This utility model discloses a high-voltage plug-in grounding structure and controller for an integrated controller. The high-voltage plug-in is mounted on the metal casing of the controller. The high-voltage plug-in includes an insulating shell and a safety grounding PIN pin built into the insulating shell. The insulating shell contains a metal shielding shell surrounding the safety grounding PIN pin. The metal shielding shell has an elastic connector that engages and fixes with the corresponding structure of the controller casing. The metal shielding shell is fixedly connected to the safety grounding PIN pin through a conductive connector. The safety grounding PIN pin is electrically connected to the controller casing in sequence through the conductive connector, the metal shielding shell, and the elastic connector. By designing the metal shielding shell as the core carrier, the grounding function of the safety grounding PIN pin and the grounding function of the high-voltage wiring harness shielding layer, two independent grounding systems, are integrated through the metal shielding shell structure. This simplifies the overall structure, reduces the number of parts and assembly steps, and greatly improves the reliability and long-term stability of the grounding connection.

Description

Technical Field

[0001] This utility model relates to the field of electric control technology for new energy vehicles, specifically to a high-voltage plug-in grounding structure for an integrated controller and its controller. Background Technology

[0002] In existing all-in-one controllers that integrate on-board chargers (OBCs), the high-voltage input module is a key component for achieving power transmission and safety isolation. This module typically contains a pin specifically defined as Protective Earth (PE). The core function of this PE pin is to provide a low-impedance, continuous, and reliable grounding path. When an insulation fault occurs in the charging system (such as a live component contacting the casing), the fault current can be quickly conducted to ground through this path, thereby triggering the upstream protection device to operate, effectively preventing the equipment casing from becoming live and ensuring personal and equipment safety.

[0003] Currently, the conventional technical solution for grounding the PE pin of a high-voltage plug is to crimp or weld an independent grounding wire to the rear end of the PE pin, and then pass the other end of the wire through a grounding terminal and use screws or other fasteners to lock it to the metal casing of the controller.

[0004] Meanwhile, to meet electromagnetic compatibility (EMC) requirements, the shielding layer of high-voltage cables also needs to be grounded at the controller end. Common grounding methods for the shielding layer include using grounding springs, such as the installation structure for reliable grounding of the shielding layer of high-voltage shielded connectors disclosed in Chinese Utility Model Patent CN211126355, and connecting the dedicated shielding ring to the outer shell after crimping.

[0005] It is evident that in existing technologies, the safety grounding function and the shielding layer grounding function are two independently implemented systems. These two grounding systems require their own wires, terminals, springs, fasteners, and other components, resulting in a complex internal structure of the controller, occupying valuable layout space, hindering product miniaturization and high-density integration, and causing low assembly efficiency and difficulty in ensuring connection reliability.

[0006] Therefore, there is an urgent need for a grounding structure that can integrate the functions of safety grounding and shielding layer grounding, fundamentally solving the problems of structural redundancy, cumbersome assembly, and insufficient reliability in existing technologies. Utility Model Content

[0007] The technical problem to be solved by this utility model is how to achieve the integrated function of safety grounding and shielding layer grounding.

[0008] In a first aspect, to solve the above-mentioned technical problems, this utility model provides a high-voltage plug-in grounding structure for an integrated controller. The high-voltage plug-in is mounted on the metal casing of the controller. The high-voltage plug-in includes an insulating shell and a safety grounding pin built into the insulating shell. The insulating shell has a built-in metal shielding shell surrounding the safety grounding pin. The metal shielding shell is provided with an elastic connector that engages and fixes with the corresponding structure of the controller shell; The metal shielding shell is fixedly connected to the safety grounding pin via a conductive connector; The safety grounding PIN is electrically connected to the controller housing in sequence through the conductive connector, the metal shielding shell, and the elastic connector.

[0009] Furthermore, the metal shielding shell is integrally formed.

[0010] Furthermore, one end of the conductive connector is fixedly connected to the safety grounding PIN pin, and the other end is fixedly connected to a pin extending from the metal shielding shell.

[0011] Furthermore, the conductive connector is welded and fixed to the pin.

[0012] Preferably, the conductive connector is a copper busbar.

[0013] Furthermore, the elastic connector is formed on the periphery of the metal shielding shell.

[0014] Preferably, the elastic connector is an elastic buckle, a spring, or a spring finger.

[0015] Preferably, the metal shielding shell is made of copper or tin-plated steel.

[0016] A second aspect of this utility model provides a controller, including a controller housing and the aforementioned high-voltage plug-in grounding structure.

[0017] Furthermore, the controller housing is provided with a coupling that mates with the elastic connector, so that when the high-voltage plug is installed in place, the elastic connector and the coupling form a stable, low-impedance electrical connection.

[0018] Compared with the prior art, the present invention has the following beneficial effects: This utility model integrates two independent grounding systems—the grounding function of the safety grounding PIN and the grounding function of the high-voltage wire harness shielding layer—through a metal shielding shell structure, using a metal shielding shell as the core carrier. This simplifies the overall structure and reduces the number of parts and assembly steps. At the same time, the combination of "welded internal connection" and "flexible external connection" greatly improves the reliability and long-term stability of the grounding connection. Attached Figure Description

[0019] Figure 1 This is an exploded view of the overall structure disclosed in the embodiment of this utility model; Figure 2 This is a schematic diagram of the overall structure of an embodiment of the present utility model.

[0020] In the picture: 10. Insulating housing; 20. Safety grounding pin; 30. Metal shielding housing; 31. Flexible connector; 40. Conductive connector; 50. Sealing ring. Detailed Implementation

[0021] To make the technical solutions and effects of this utility model clearer, the technical solutions of this utility model will be clearly and completely described below with reference to the accompanying drawings in the embodiments. Obviously, the described embodiments are some embodiments of this utility model, but not all embodiments.

[0022] This utility model aims to provide a high-voltage plug-in grounding structure for integrated controllers. By designing a metal shielding shell as the core carrier, the grounding function of the safety grounding PIN pin and the grounding function of the high-voltage wire harness shielding layer, two independent grounding systems, are integrated through the metal shielding shell structure. This simplifies the overall structure, reduces the number of parts and assembly steps, and provides a reliable and stable grounding connection.

[0023] The high-voltage connector is mounted on the metal casing of the controller. One end of the connector is a quick-connect interface for connecting to the charging pile wiring harness, and the other end connects to the internal circuitry of the OBC. A safety grounding pin is located within this high-voltage connector. The high-voltage connector includes an insulating housing 10 and a safety grounding pin 20 built into the insulating housing 10.

[0024] Please see Figure 1-2 The insulating housing 10 contains a metal shielding shell 30 that surrounds the safety grounding PIN pin 20, and a sealing ring 50 is provided between the metal shielding shell 30 and the insulating housing 10. The metal shielding shell 30 is integrally formed and made of copper or tin-plated steel. The metal shielding shell 30 surrounds the high-voltage signal safety grounding PIN pin 20, and its primary function is to provide a grounding point and electromagnetic shielding for the shielding layer of the high-voltage harness.

[0025] In this design, the metal shielding shell 30 is provided with an elastic connector 31 that engages and is fixed to the corresponding structure of the controller housing; the metal shielding shell 30 is fixedly connected to the safety grounding PIN pin 20 through the conductive connector 40; the metal shielding shell 30 is fixedly connected to the safety grounding PIN pin 20 through the conductive connector 40; so that the safety grounding PIN pin 20 is electrically connected to the controller housing in sequence through the conductive connector 40, the metal shielding shell 30 and the elastic connector 31.

[0026] As can be seen, the metal shielding shell 30 in this solution is not only the electromagnetic shield of the high-voltage signal safety grounding PIN, but also acts as a conduction bridge for the safety grounding current, realizing the dual function of safety grounding and electromagnetic shielding grounding.

[0027] In this design, one end of the conductive connector 40 is fixedly connected to the safety grounding PIN pin 20, and the other end is fixedly connected to one or more pins extending from the metal shielding shell 30. Preferably, the conductive connector 40 is welded to the pins, such as by laser welding or resistance welding, reducing mechanical connection points and achieving a robust and permanent physical and electrical connection. Thus, the current from the safety grounding PIN pin 20 can be directly and with low loss conducted to the metal shielding shell 30 through the conductive connector 40. Optionally, the conductive connector 40 is a copper busbar. The copper busbar, as the main current conduction channel, has the advantages of a large cross-sectional area, good conductivity, and strong current carrying capacity, ensuring that fault current can be quickly discharged.

[0028] The metal shielding shell 30 has an elastic connector 31 formed around its periphery. Optionally, the elastic connector 31 can be an elastic buckle, a spring, or a spring finger, etc.

[0029] Furthermore, this utility model also protects a controller, which includes a controller housing and the aforementioned high-voltage plug-in grounding structure. In a further embodiment, the controller housing is provided with a coupling that mates with the elastic connector 31; this coupling can be a corresponding opening or groove. When the high-voltage plug-in is inserted into and fixed to the OBC's controller housing, the elastic connector 31 and the corresponding opening or groove of the controller housing undergo elastic deformation and tightly engage, forming a stable, low-impedance, and vibration-resistant electrical connection point.

[0030] Thus, in a specific example, a highly integrated direct-connect, low-impedance grounding path is established: safety grounding PIN 20 → metal copper busbar → metal shield shell 30 pin (soldering point) → metal shield shell 30 → elastic clip → controller housing → ground.

[0031] On the one hand, it abandons the traditional multi-level mechanical connection mode of safety grounding pin → wire → terminal → screw → controller housing → ground, which simplifies the structure, increases space utilization, and is conducive to the miniaturization and lightweight design of the product.

[0032] On the other hand, the assembly process is greatly simplified. The high-voltage plug-in only needs to be inserted into the control housing and fixed. The grounding connection and shielding grounding can be completed automatically through the elastic buckle, which improves production efficiency and consistency and reduces assembly difficulty.

[0033] At the same time, the shielding layer of the high-voltage input harness is connected to the plug housing (conductive with the metal shielding shell 30) at the quick-connect interface end, realizing the integration of "safety grounding" and "shielding grounding" into one, which is a clever integrated innovation in the field of high-voltage connector design.

[0034] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A high-voltage plug-in grounding structure for an integrated controller, the high-voltage plug-in being mounted on a metal housing of the controller, the high-voltage plug-in comprising an insulating housing (10) and a safety grounding PIN (20) embedded in the insulating housing (10), characterized in that, The insulating housing (10) contains a metal shielding shell (30) that surrounds the safety grounding PIN (20): The metal shielding shell (30) is provided with an elastic connector (31) that engages and is fixed to the corresponding structure of the controller shell. The metal shielding shell (30) is fixedly connected to the safety grounding pin (20) via a conductive connector (40); The safety grounding PIN (20) is electrically connected to the controller housing in sequence through the conductive connector (40), the metal shield (30) and the elastic connector (31).

2. The high-voltage plug-in grounding structure for an integrated controller according to claim 1, characterized in that, The metal shielding shell (30) is integrally formed.

3. The high-voltage plug-in grounding structure for an integrated controller according to claim 1, characterized in that, One end of the conductive connector (40) is fixedly connected to the safety grounding PIN (20), and the other end is fixedly connected to a pin extending from the metal shield (30).

4. The high-voltage plug-in grounding structure for an integrated controller according to claim 3, characterized in that, The conductive connector (40) is welded and fixed to the pin.

5. The high-voltage plug-in grounding structure for an integrated controller according to claim 1 or 3, characterized in that, The conductive connector (40) is a copper busbar.

6. The high-voltage plug-in grounding structure for an integrated controller according to claim 1, characterized in that, The elastic connector (31) is formed on the periphery of the metal shielding shell (30).

7. The high-voltage plug-in grounding structure for an integrated controller according to claim 1 or 6, characterized in that, The elastic connector (31) is an elastic buckle, a spring, or a spring finger.

8. The high-voltage plug-in grounding structure for an integrated controller according to claim 1, characterized in that, The metal shielding shell (30) is made of copper or tin-plated steel.

9. A controller, characterized in that, It includes a controller housing and a high-voltage plug-in grounding structure as described in any one of claims 1-8.

10. The controller according to claim 9, characterized in that, The controller housing is provided with a coupling that cooperates with the elastic connector (31), so that when the high voltage plug is installed in place, the elastic connector (31) and the coupling form a stable electrical connection.

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