Wide voltage range control ac distribution box

Abstract

The utility model discloses a wide voltage range control ac distribution box has solved the problem of poor adaptability of the prior art ac distribution box, the problem of low voltage energy loss increase, the utility model discloses a box body is equipped with relay group and relay drive hardware circuit in the box body, and relay group is connected with relay drive hardware circuit electrically, and relay drive hardware circuit includes DCDC chip, relay drive module and filter, and relay drive module and filter all are connected with DCDC chip electrically, and relay drive module and DCDC chip all are connected with relay group electrically, and the wide low voltage power supply of wide low voltage input module is powered for relay group after the filter input DCDC chip, and the relay control signal of VIU module controls whether the relay group is closed through relay drive module. The utility model discloses through having increased relay drive hardware circuit in ac distribution box, has increased the universal adaptability and platformization popularization of ac distribution box.

Description

Technical Field

[0001] This utility model relates to the field of power control technology for new energy vehicles, and in particular to an AC power distribution box, which is applicable to scenarios such as electric vehicle charging and discharging management and power distribution for special vehicles. Background Technology

[0002] A bidirectional OBC (On-Board Charger) for new energy vehicles is a key device enabling rapid charging and discharging of electric vehicle batteries. It mainly consists of an AC input terminal, a DC output terminal, an intermediate transformer, a controller, and circuit protection components. Its working principle involves converting AC power into high-frequency AC power, which is then transformed by the intermediate transformer and output to the battery pack, achieving rapid charging. When the battery needs to discharge, the bidirectional OBC uses reverse control to convert the DC power in the battery into high-frequency AC power, which is then transformed by the intermediate transformer and output to the AC grid, achieving rapid discharging. Furthermore, the bidirectional OBC also has circuit protection functions, monitoring and protecting the battery pack, charger, and output terminal to ensure the safe and stable operation of the electric vehicle.

[0003] However, in-vehicle high-voltage power distribution units primarily distribute DC power, with very few AC power distribution units. Furthermore, the circuit designs for external and internal discharge are generally independent, lacking integrated power distribution design units. With the rapid development of new energy vehicles, the demand for internal and external discharge functions has been widely mentioned. To meet customer functional requirements, many automakers have developed power distribution units that distribute power via AC relays. Simultaneously, controller designs have been modified to meet the control and drive requirements of AC relays, resulting in significant modifications to existing equipment and poor adaptability.

[0004] The current vehicle high-voltage power distribution scheme has the following significant limitations: (1) Single power distribution type: The high-voltage power distribution unit (PDU) only supports DC power distribution and lacks AC power distribution capability, which means that AC loads (such as V2L / V2G) need to be equipped with an additional independent circuit; (2) System separation and redundancy: The external discharge (V2X) and the internal AC power supply system are designed completely independently, which causes the following problems: Repetitive configuration of relays, fuses and other devices → increased volume / cost; Separation of control logic → low energy dispatch efficiency; Inability to coordinate safety protection mechanisms → delayed fault response; (3) Topology rigidity: Traditional PDUs cannot reuse the bidirectional energy path of OBC, which restricts the improvement of system integration.

[0005] To meet the growing demand for AC power inside and outside the vehicle (camping power supply, emergency power supply, etc.), some car manufacturers have adopted improved solutions: (1) AC relay embedded in PDU: adding an AC relay module to the DC power distribution architecture to realize basic AC switching function; (2) Controller compatibility modification: adjusting the controller drive circuit to support AC relay control signal output. However, such solutions still have essential defects: 1. Additional voltage regulation circuit design: adding a separate drive AC relay drive power output module → low voltage energy loss increases by more than 15%; 2. Lack of dynamic switching: unable to dynamically reconstruct electrical connections according to the operating mode (charging / discharging / in-vehicle power supply); 3. Safety bottleneck: the separate protection mechanism leads to blind spots in fault detection coverage (such as the risk of arcing at the OBC and PDU interface). Utility Model Content

[0006] To address the shortcomings in the aforementioned background technology, this utility model proposes a wide voltage range control AC power distribution box, which solves the problems of poor adaptability and increased low-voltage energy loss in the existing AC power distribution box.

[0007] The technical solution of this utility model is implemented as follows: A wide voltage range control AC power distribution box includes a box body, within which a relay group and a relay driving hardware circuit are disposed. The relay group and the relay driving hardware circuit are electrically connected. The relay driving hardware circuit includes a DC-DC chip, a relay driving module, and a filter. The relay driving module and the filter are both electrically connected to the DC-DC chip, and both the relay driving module and the DC-DC chip are electrically connected to the relay group. The wide low-voltage power supply of the wide low-voltage input module is input to the DC-DC chip through the filter to power the relay group. The relay control signal of the VIU module controls whether the relay group is closed or not through the relay driving module. This technical solution increases the universal adaptability and platform-based promotion of the AC power distribution box by adding a relay driving hardware circuit to the AC power distribution box. It can perform AC power distribution function simply by using an enable signal line without changing the internal circuit of the vehicle body controller. Due to the addition of the low-voltage power supply circuit, the input voltage range of the low-voltage control power supply can be further expanded, increasing the adaptability of the AC power distribution box. This allows it to be applied not only in the passenger car field but also in commercial vehicles and construction machinery that require AC power distribution. The application of this technology will reduce the development and design costs of vehicle AC power distribution boxes, shorten the development cycle of vehicle AC power distribution boxes, and facilitate the application and promotion of multiple platforms and vehicle models.

[0008] Further preferably, the housing is equipped with a low-voltage communication interface, an OBC interface, an external AC output interface, and an internal AC output interface. The low-voltage communication interface is used for inputting wide-range low-voltage power supplies, relay control signals, etc., from the low-voltage input module; the OBC interface is used for connection to the on-board charger (OBC); the external AC output interface is used for connecting external AC output components; and the internal AC output interface is used for connecting internal output components.

[0009] Further optimization reveals that the relay group includes a first high-side relay K1, a first low-side relay K2, a second high-side relay K3, and a second low-side relay K4. The relay driver hardware circuit controls the connection between the external AC output interface and the OBC interface through the first high-side relay K1 and the first low-side relay K2, and the relay driver hardware circuit controls the connection between the external AC output interface and the OBC interface through the second high-side relay K3 and the second low-side relay K4. By configuring K1 / K2 and K3 / K4 as a "dual high-low side relay" in parallel, four functions can be achieved: bidirectional V2L / V2G operation of the power distribution box, redundant disconnection, simultaneous disconnection of live and neutral circuits, and energy saving under light load.

[0010] Further preferably, the relay drive module includes transistors K1-K2 electrically connected to the first high-side relay K1 and the first low-side relay K2, and transistors K3-K4 electrically connected to the second high-side relay K3 and the second low-side relay K4. Transistors K1-K2 serve as switches for the first high-side relay K1 and the first low-side relay K2. Transistors K3-K4 serve as switches for the second high-side relay K3 and the second low-side relay K4.

[0011] In a further preferred embodiment, the DC-DC chip includes a comparator, an integrated H-bridge converter, and an ADC acquisition module. The input terminal of the comparator is electrically connected to a filter, the output terminal of the comparator is electrically connected to the integrated H-bridge converter, the input terminal of the ADC acquisition module is electrically connected to the output terminal of the integrated H-bridge converter, and the output terminal of the ADC acquisition module is electrically connected to the comparator.

[0012] Further optimization involves an integrated H-bridge converter employing a three-mode DC-DC conversion circuit. The input of the integrated H-bridge converter is connected to an H-bridge drive circuit, and the input of the H-bridge drive circuit is connected to an OR gate diode. The OR gate diode controls whether the relay control signal from the VIU module drives the H-bridge drive circuit. A temperature sensor is connected to the H-bridge drive circuit.

[0013] Further optimization reveals that the wide low-voltage input module has a power supply range of 6~40V. This power supply, after being filtered and input to the DC-DC chip, outputs 12V. This invention utilizes an automotive-grade DC-DC control chip to stabilize the 6VDC~40VDC DC input voltage to the 12VDC drive voltage required by the AC relay, effectively ensuring the relay coil's operation over a wide temperature range.

[0014] The beneficial effects of this utility model are as follows: By adding a relay drive hardware circuit to the AC power distribution box, this utility model increases the universality and platform-based promotion of the AC power distribution box. It allows for AC power distribution functionality solely through the enable signal line without altering the internal circuitry of the vehicle body controller. The addition of the low-voltage power supply circuit further expands the input voltage range of the low-voltage control power supply from the original 9~16VDC to 6~40VDC, increasing the adaptability of the AC power distribution box. This allows it to be applied not only in passenger vehicles but also in commercial vehicles and construction machinery requiring AC power distribution.

[0015] This invention utilizes an onboard DC-DC control chip to stabilize the 6VDC~40VDC DC input voltage to the 12VDC drive voltage required by the AC relay, effectively ensuring the relay coil's operation over a wide temperature range. Furthermore, it employs voltage drive, using discrete components to form an OR gate circuit to enable the power management chip, thereby outputting a stable 12VDC voltage. Simultaneously, an NPN transistor low-side drive method activates the corresponding enable circuit relay, thus enabling selective conduction of either the in-vehicle or external circuit. The application of this invention will reduce the development and design costs of onboard AC power distribution boxes, shorten the development cycle, and facilitate application and promotion across multiple platforms and vehicle models. Attached Figure Description

[0016] To more clearly illustrate the embodiments of this utility model, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of the principle of the AC high-voltage distribution box with wide voltage range control according to this utility model.

[0018] Figure 2 This is a schematic diagram of the relay driver hardware circuit of this utility model. Detailed Implementation

[0019] 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.

[0020] Example 1, such as Figure 1 As shown, a wide voltage range control AC power distribution box includes a box body 1, within which a relay group 2 and a relay driver hardware circuit 3 are installed. The relay group 2 and the relay driver hardware circuit 3 are electrically connected. The relay group 2 and the relay driver hardware circuit 3 are integrated within the box body. This solution increases the universality and platform-based promotion of the AC power distribution box by adding a relay driver hardware circuit. It allows AC power distribution functions to be performed solely through an enable signal line without altering the internal circuitry of the vehicle body controller. In this embodiment, the relay driver hardware circuit 3 includes a DC-DC chip 31, a relay driver module 32, and a filter 33. Both the relay driver module 32 and the filter 33 are electrically connected to the DC-DC chip 31, and both are electrically connected to the relay group 2. The wide low-voltage power supply from the wide low-voltage input module is input to the DC-DC chip 31 via the filter 33 to power the relay group 2. The relay control signal from the VIU module controls the closure of the relay group 2 via the relay driver module 32. A low-pass filter is used to prevent power supply harmonic interference. The wide low-voltage input module has a power supply range of 6~40V. After passing through filter 33 and inputting to DC-DC chip 31, the wide low-voltage input module outputs 12V, providing a stable 12V power supply for the relay. Employing full-range voltage coverage technology, a single circuit supports voltages from cold start low (6VDC) to load dump high (40VDC), breaking through the traditional 9-32VDC limitation of vehicle controllers. The integrated design of wide-voltage DC-DC, constant current drive, and pre-filter allows the AC distribution box to achieve "any connection from 6~40V, doubled relay lifespan, EMC pass on the first attempt, tripping even with a neutral wire disconnection, and halved wiring harness requirements," resulting in a lower overall cost.

[0021] This invention utilizes an onboard DC-DC control chip to stabilize a 6VDC~40VDC DC input voltage to the 12VDC drive voltage required by the AC relay, effectively ensuring the relay coil's operation over a wide temperature range. The invention employs the Silergy SA22307 as the main control chip for the DC-DC circuit. This chip converts the input 6VDC~40VDC low-voltage control voltage into a stable 12VDC output, with a drive current of 0.2~3A. This chip can operate in three modes (Buck mode (16-40VDC input), Boost mode (6-12VDC input), and Buck-Boost mode (12-16VDC input)) to regulate the 6-40VDC to 12VDC voltage. Due to the addition of the low-voltage power supply circuit, the input voltage range of the low-voltage control power supply can be further expanded from the original 9~16VDC to 6~40VDC, increasing the adaptability of the AC power distribution box. This allows it to be applied not only in passenger vehicles but also in commercial vehicles and construction machinery requiring AC power distribution. The application of this technology will reduce the development and design costs of automotive AC power distribution boxes, shorten the development cycle, and facilitate application and promotion across multiple platforms and vehicle models. By adding a low-voltage drive power supply circuit, only an enable signal with a drive voltage of 6VDC or higher is needed to control the AC high-voltage circuit. This invention effectively separates and integrates the drive power supply circuit, reducing the design difficulty of the controller and increasing the versatility of the AC high-voltage power distribution box.

[0022] Example 2, as Figure 2 As shown, a wide voltage range control AC power distribution box is further optimized based on Embodiment 1. In this embodiment, the box body is provided with a low-voltage communication interface, an OBC interface, an external AC output interface, and an internal AC output interface. The low-voltage communication interface is used to connect with low-voltage communication connector components and is used for inputting wide low-voltage power supplies, relay control signals, etc., from the low-voltage wide-range input module. The OBC interface is used to connect with the on-board charger (OBC); the external AC output interface is used to connect external AC output components, and the internal AC output interface is used to connect internal output components.

[0023] In this preferred embodiment, relay group 2 includes a first high-side relay K1, a first low-side relay K2, a second high-side relay K3, and a second low-side relay K4. The relay driving hardware circuit 3 controls the connection between the external AC output interface and the OBC interface via the first high-side relay K1 and the first low-side relay K2. Similarly, the relay driving hardware circuit 3 controls the connection between the external AC output interface and the OBC interface via the second high-side relay K3 and the second low-side relay K4. By configuring K1 / K2 and K3 / K4 as a "dual high-low side relay" in parallel, the current is halved, redundant interruption is achieved, and the triple benefits of "functional safety + flexible topology + halved heat loss" are realized.

[0024] In this preferred embodiment, the relay drive module 32 includes transistors K1-K2 electrically connected to the first high-side relay K1 and the first low-side relay K2, and transistors K3-K4 electrically connected to the second high-side relay K3 and the second low-side relay K4. The relay control signals of the VIU module are divided into K1-K2 enable and K3-K4 enable. The K1-K2 enable controls the first high-side relay K1 and the first low-side relay K2 to perform corresponding actions through the K1-K2 transistors, and the K3-K4 enable controls the second high-side relay K3 and the second low-side relay K4 to perform corresponding actions through the K3-K4 transistors.

[0025] The DC-DC chip 31 includes a comparator 311, an integrated H-bridge converter 312, and an ADC acquisition module 313. The ADC acquisition module 313 is used for acquiring the output voltage signal. The input terminal of the comparator 311 is electrically connected to the filter 33, and the output terminal of the comparator 311 is electrically connected to the integrated H-bridge converter 312. The input terminal of the ADC acquisition module 313 is electrically connected to the output terminal of the integrated H-bridge converter 312, and the output terminal of the ADC acquisition module 313 is electrically connected to the comparator 311. The DC-DC chip uses a Kelvin current sampling circuit, which effectively implements the output short-circuit protection function, making the wide voltage design more stable and reliable. The integrated H-bridge converter 312 integrates an H-bridge MOSFET circuit and adopts a three-mode DC-DC conversion circuit. Its three-mode switching logic is as follows: when the input power supply V_in < 12V, Boost mode is used; when 12V ≤ V_in ≤ 16V, Buck-Boost mode is used; and when V_in > 16V, Buck mode is used.

[0026] In this embodiment, the input terminal of the integrated H-bridge converter 312 is connected to an H-bridge drive circuit 314, and the input terminal of the H-bridge drive circuit 314 is connected to an OR gate diode 316. Based on capacitor isolation technology, dual-channel signal transmission is used, and the OR gate diode 316 controls whether the relay control signal of the VIU module drives the H-bridge drive circuit 314. A temperature sensor 315 is connected to the H-bridge drive circuit 314; a voltage / temperature dual compensation mechanism ensures stability across the entire temperature range of -40℃ to 125℃. When the chip is not enabled, the static operating current at room temperature is less than 1μA, achieving low power consumption when used in the entire system without a relay enable signal.

[0027] The relay control is implemented by a relay driver hardware circuit. The vehicle's constant power and control signals are input to the relay driver hardware circuit via a low-voltage communication interface. The constant power voltage range is 6~40V. The hardware circuit filters the power supply voltage through a low-pass filter, effectively eliminating power supply harmonic interference. Voltage conversion is achieved through an H-bridge circuit composed of 7 AMOS FFETs integrated into the DC-DC chip. Based on the feedback voltage from the ADC acquisition module, the chip switches between Boost mode, Buck-Boost mode, and Buck mode under the coordination of the safety interlock state machine and comparator. Simultaneously, the DC-DC chip also has an enable function. The control signal input from the low-voltage communication interface is used to enable the temperature-compensated H-bridge driver circuit within the chip through an isolated OR gate enable circuit, thereby controlling the H-bridge's operating state and achieving a stable 12V output from the relay power supply. Furthermore, the high-voltage connector interlock signal of this invention is connected in series through an internal circuit board and ultimately output to the vehicle from the low-voltage connector, enabling the vehicle to monitor the high-voltage connector connection status.

[0028] It should be noted that this utility model improves the equipment components and does not involve improvements to the circuitry or control program. This utility model only controls the operation and shutdown of various electronic devices through a PLC control system. Since PLC control systems are mature automatic control systems in industry, this utility model will not elaborate on the circuitry and control program content. Furthermore, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections or electrical connections; they can refer to direct connections or indirect connections through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention through the specific circumstances.

[0029] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A wide voltage range control AC distribution box comprising a box body (1), characterized in that: The box (1) contains a relay group (2) and a relay driving hardware circuit (3), and the relay group (2) and the relay driving hardware circuit (3) are electrically connected. The relay drive hardware circuit (3) includes a DC-DC chip (31), a relay drive module (32), and a filter (33). The relay drive module (32) and the filter (33) are both electrically connected to the DC-DC chip (31). The relay drive module (32) and the DC-DC chip (31) are both electrically connected to the relay group (2). The wide low voltage power supply of the wide low voltage input module is input to the DC-DC chip (31) through the filter (33) to power the relay group (2). The relay control signal of the VIU module controls whether the relay group (2) is closed or not through the relay drive module (32).

2. The wide voltage range control AC power distribution box of claim 1, wherein: The box is equipped with a low-voltage communication interface, an OBC interface, an external AC output interface, and an internal AC output interface.

3. The wide voltage range control AC distribution box according to claim 2, characterized in that: The relay group (2) includes a first high-side relay K1, a first low-side relay K2, a second high-side relay K3, and a second low-side relay K4. The relay driving hardware circuit (3) controls whether the external AC output interface and the OBC interface are connected through the first high-side relay K1 and the first low-side relay K2. The relay driving hardware circuit (3) controls whether the external AC output interface and the OBC interface are connected through the second high-side relay K3 and the second low-side relay K4.

4. The wide voltage range control AC power distribution box of claim 3, wherein: The relay drive module (32) includes K1-K2 transistors electrically connected to the first high-side relay K1 and the first low-side relay K2, and K3-K4 transistors electrically connected to the second high-side relay K3 and the second low-side relay K4.

5. The wide voltage range control AC power distribution box of claim 4, wherein: The DC-DC chip (31) includes a comparator (311), an integrated H-bridge converter (312), and an ADC acquisition module (313). The input terminal of the comparator (311) is electrically connected to the filter (33), the output terminal of the comparator (311) is electrically connected to the integrated H-bridge converter (312), the input terminal of the ADC acquisition module (313) is electrically connected to the output terminal of the integrated H-bridge converter (312), and the output terminal of the ADC acquisition module (313) is electrically connected to the comparator (311).

6. The wide voltage range control AC power distribution box of claim 5, wherein: The integrated H-bridge converter (312) adopts a three-mode DC-DC conversion circuit; the input terminal of the integrated H-bridge converter (312) is connected to an H-bridge drive circuit (314), and the input terminal of the H-bridge drive circuit (314) is connected to an OR gate diode (316). The OR gate diode (316) controls whether the relay control signal of the VIU module drives the H-bridge drive circuit (314).

7. The wide voltage range control AC distribution box according to claim 6, characterized in that: A temperature sensor (315) is connected to the H-bridge drive circuit (314).

8. The wide voltage range control AC distribution box according to any one of claims 1 to 7, characterized in that: The wide low-voltage input module has a wide low-voltage power supply range of 6~40V.

9. The wide voltage range control AC power distribution box of claim 8, wherein: The wide low voltage power supply of the wide low voltage input module is input to the DCDC chip (31) through the filter (33) and outputs a 12V power supply.

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