New energy heavy truck bdu integrated support system

Abstract

The utility model relates to new energy heavy truck electrical system installation technical field discloses a new energy heavy truck BDU integrated support system, including BDU integrated support, support connecting plate and a plurality of function installation structure, BDU integrated support is frame structure, through support connecting plate and the frame connection of new energy heavy truck, function installation structure includes installation plane, welding support and screw joint distribution box support, installation plane is used to install BDU and VCU, welding support is used for fixing BMS and PSR, screw joint distribution box support is used for fixing LPDU, BDU integrated support is overlapped and welded by three layers of groove type bending piece, including lower longitudinal beam, lower crossbeam, middle vertical, upper crossbeam and upper longitudinal beam, lower longitudinal beam and lower crossbeam constitute lower frame, upper crossbeam and upper longitudinal beam constitute installation plane, can realize high integrated degree, reliable structure, installation nimble and convenient maintenance.

Description

Technical Field

[0001] This utility model relates to the field of electrical system installation technology for new energy heavy trucks, specifically to a BDU integrated bracket system for new energy heavy trucks. Background Technology

[0002] With the rapid development of the new energy vehicle industry, new energy heavy trucks have been widely used due to their environmental protection and energy-saving advantages. As the "core switching hub" of the high-voltage electrical system of new energy heavy trucks, the BDU (Battery Distribution Unit) controls the power-on and power-off, pre-charging and charging processes of the high-voltage electrical circuits, and is crucial to the service life of the vehicle, control strategy and high-voltage electrical safety.

[0003] Currently, the installation methods of BDU (Battery Distribution Unit) in new energy heavy trucks are mainly divided into two categories: one is to install it inside or near the power battery pack. Although this method can reduce the length of the high-voltage wiring harness, it occupies the internal space of the battery pack and makes maintenance and replacement inconvenient; the other is to install it independently of the battery in other locations on the vehicle. Although this improves the flexibility of installation, in the existing independent installation schemes, electrical components such as BDU (Battery Distribution Unit Assembly), BMS (Battery Management System), VCU (Vehicle Controller Unit), LPDU (Low Voltage Distribution Unit), and PSR (Power Relay) are mostly installed separately using separate brackets.

[0004] This decentralized installation mode has many drawbacks: First, multiple independent brackets result in low space utilization and a crowded overall vehicle layout; second, the large number of brackets increases the vehicle's weight, affecting its range; third, decentralized installation is prone to bracket loosening, which can pull on the wiring and cause damage, posing a safety hazard; fourth, maintenance requires disassembling multiple brackets separately, which is cumbersome and increases maintenance costs and time; fifth, traditional bracket structures are redundant, have insufficient weldability and strength, and their fixed installation positions make it difficult to adapt to different vehicle height requirements. Utility Model Content

[0005] The present invention aims to provide an integrated bracket system for BDU in new energy heavy trucks, in order to solve the problems of low space utilization, large weight, inconvenient maintenance, and easy loosening and damage of wiring caused by the scattered installation of multiple high-voltage electrical components such as BDU and BMS in existing new energy heavy trucks.

[0006] To solve the above problems, the present invention adopts the following technical solution: Basic Solution: A new energy heavy-duty truck BDU integrated bracket system includes a BDU integrated bracket, a bracket connecting plate, and multiple functional mounting structures. The BDU integrated bracket is a frame structure, connected to the frame of the new energy heavy-duty truck via the bracket connecting plate. The functional mounting structures include a mounting plane, a welding bracket, and a screw-connected distribution box bracket. The mounting plane is used to mount the BDU and VCU, the welding bracket is used to fix the BMS and PSR, and the screw-connected distribution box bracket is used to fix the LPDU. The BDU integrated bracket is formed by overlapping and welding three layers of grooved bending parts, including a lower longitudinal beam, a lower crossbeam, a middle vertical beam, an upper crossbeam, and an upper longitudinal beam. The lower longitudinal beam and the lower crossbeam form the lower frame, and the upper crossbeam and the upper longitudinal beam form the mounting plane.

[0007] Beneficial effects: It enables centralized installation of multiple components such as BDU, BMS, VCU, LPDU, and PSR, avoiding the waste of space and weight caused by decentralized installation, improving space utilization, reducing overall weight, and reducing the risk of damage from loose wiring. The structural design of the channel-shaped bending parts with welded connections improves weldability and strength, while reducing structural redundancy and further reducing the weight of the bracket.

[0008] Furthermore, the bracket connecting plate includes a connecting bracket one and a connecting bracket two. The BDU integrated bracket is screwed to the connecting bracket one and the connecting bracket two through side mounting holes. The ends of the connecting bracket one and the connecting bracket two away from the BDU integrated bracket are fixedly connected to the vehicle frame.

[0009] Beneficial effects: The bracket connection plate enables a stable connection between the BDU integrated bracket and the vehicle frame, making installation and disassembly convenient and facilitating later maintenance.

[0010] Furthermore, a suspension pad is provided between the first connecting bracket and the second connecting bracket, and the number of the suspension pads is 2-4, which are evenly distributed along the length direction of the first connecting bracket and the second connecting bracket.

[0011] Beneficial effects: The suspension pads enhance the overall cushioning capacity, reduce the impact of vibrations on electrical components during vehicle operation, and extend the service life of components.

[0012] Furthermore, the welding bracket includes a BDU welding bracket, a PSR welding bracket, a VCU welding bracket, and a BMS welding bracket; the BDU welding bracket, PSR welding bracket, and VCU welding bracket are all fixed to the mounting plane, and the BMS welding bracket is welded laterally in parallel to the front of the BDU integrated bracket.

[0013] Beneficial effects: The dedicated welding bracket provides precise installation positioning for each component, ensuring installation stability, while also facilitating rapid assembly of components.

[0014] Furthermore, the BDU integrated bracket is welded with wire harness brackets, and the number of wire harness brackets is 3-5, which are used to bundle and fix water pipes and electrical wire harnesses.

[0015] Beneficial effects: The wire harness bracket enables the orderly fixation of water pipes and electrical wire harnesses, avoids messy tangling of wires, reduces the risk of wire wear, and facilitates wire maintenance.

[0016] Furthermore, a lower connecting bracket is provided on the lower side of the BDU integrated bracket, which is used to install the multi-in-one controller, and the multi-in-one controller is arranged vertically above the BDU.

[0017] Beneficial effects: Provides installation space for the all-in-one controller, improves space utilization, and the vertical arrangement facilitates connection between the two, reducing the length of high-voltage wiring harnesses.

[0018] Furthermore, the height of the bracket connecting plate is adjustable, with an adjustment range of 80-200mm.

[0019] Beneficial effects: It can adapt to different vehicle height requirements without the need for frequent replacement of BDU integrated brackets, thus improving the versatility of the bracket.

[0020] Furthermore, the upper longitudinal beam includes an upper longitudinal beam one and an upper longitudinal beam two, which are arranged in parallel. The number of upper crossbeams is two, which are respectively connected to the two ends of the upper longitudinal beam one and the upper longitudinal beam two.

[0021] Beneficial effects: Optimizes the stability of the frame structure, ensures the flatness of the mounting surface, and provides a reliable mounting foundation for BDU and VCU.

[0022] Furthermore, the mounting plane of the screw-connected distribution box bracket and the BDU integrated bracket is fixedly connected by four bolts.

[0023] Beneficial effects: Ensures the stability of the LPDU installation, prevents the LPDU from loosening due to vibration during vehicle operation, and improves safety during use.

[0024] Advantages of this utility model: 1. High integration: Multiple components such as BDU, BMS, VCU, LPDU, and PSR can be assembled on the same bracket at the same time, reducing the number of independent brackets, improving space utilization, and reducing the overall vehicle weight.

[0025] 2. Reliable structure: It is made of grooved bending parts lap welding, which improves weldability and welding strength, reduces structural redundancy, and the design of suspended soft pads enhances the buffering capacity and resists the impact of vibration.

[0026] 3. Flexible installation: The mounting surface can be rotated through the bracket connecting plate, avoiding the need for drilling holes on the upper part of the frame, and the height of the bracket connecting plate can be adjusted to meet the needs of different vehicle heights.

[0027] 4. Convenient maintenance: The centralized installation design facilitates unified inspection and replacement of components. The multi-in-one controller and BDU are arranged vertically, reducing the length of high-voltage wiring harnesses and lowering maintenance costs.

[0028] 5. Organized wiring: The wire harness bracket provides bundling and fixing points for water pipes and electrical wire harnesses, avoiding messy wiring and reducing the risk of loose and damaged wiring. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the BDU integrated bracket assembly structure according to an embodiment of the present utility model.

[0030] Figure 2 This is a schematic diagram of the BDU installation according to an embodiment of the present utility model.

[0031] Figure 3 This is a schematic diagram of the structure of the BDU integrated bracket in an embodiment of this utility model.

[0032] Figure 4 This is a schematic diagram of the multi-in-one installation in an embodiment of this utility model; The reference numerals in the accompanying drawings include: BDU integrated bracket 1, connecting bracket one 2, connecting bracket two 3, suspension pad 4, low-voltage distribution box bracket 5, steering oil tank bracket 6, lower longitudinal beam 7, lower crossbeam 8, middle vertical beam 9, upper crossbeam 10, upper longitudinal beam one 11, upper longitudinal beam two 12, BDU welding bracket 13, PSR welding bracket 14, VCU welding bracket 15, BMS welding bracket 16, wiring harness bracket 17, and multi-function controller bracket 18. Detailed Implementation

[0033] The following detailed description illustrates the specific implementation method: like Figure 2 As shown, this utility model's new energy heavy-duty truck BDU integrated bracket system integrates the installation of BDU, BMS, VCU, LPDU, and PSR. The BDU and VCU are installed via the mounting plane of the integrated bracket, the BMS and PSR are fixed via welded brackets on the integrated bracket, and the LPDU is fixed via a screw-connected distribution box bracket on the mounting plane of the integrated bracket. This type of BDU bracket is screwed to the bracket connecting plate via side mounting holes, and is connected to the vehicle frame via the bracket connecting plate.

[0034] This utility model has the following characteristics: 1. Integrated installation design: Multiple components such as BDU, BMS, VCU, LPDU, and PSR can be installed on the same bracket at the same time. This avoids the waste of space and weight caused by installing components separately on the bracket, improves space utilization, reduces overall weight, and has a high degree of integration. It also reduces the problem of loosening and damage to the lines caused by bracket loosening.

[0035] 2. The grooved bending parts are connected by welding to improve weldability and welding strength, while reducing structural redundancy and lowering the weight.

[0036] 3. The mounting surface is repositioned, and the mounting surface of the BDU integrated bracket is repositioned to the side of the frame using a bracket connecting plate, avoiding the need for openings on the upper part of the frame; at the same time, the overall height of the BDU can be adjusted by controlling the height of the bracket connecting plate, avoiding frequent replacement of the BDU integrated bracket; a suspension pad is connected between the upper and lower connecting plates to enhance the overall cushioning capacity.

[0037] 4. The lifting frame structure facilitates cable routing and provides installation and maintenance space for the multi-function controller located on the lower side. The multi-function controller and BDU are arranged vertically for easy connection and to reduce the length of the high-voltage wiring harness.

[0038] like Figure 1 , Figure 2 As shown, the BDU integrated bracket system consists of BDU integrated bracket 1 and lower connecting brackets screwed together. A suspension pad 4 is arranged between connecting brackets 2 and 3. The BDU and VCU are installed on the upper plane of the BDU integrated bracket, and the BMS is installed on the front welded bracket. The steering oil tank and the low-voltage distribution box are screwed to the BDU integrated bracket 1 through the steering oil tank bracket 6 and the low-voltage distribution box bracket 5.

[0039] like Figure 3 As shown, the integrated bracket 1 is a frame structure, consisting of a lower layer of longitudinal beams 7 and transverse beams 8, a middle layer of vertical beams 9, and an upper layer of transverse beams 10, longitudinal beams 11, and longitudinal beams 12, which are lapped and welded together by three layers of channel-shaped bent parts. The upper plane, together with the BDU welding bracket 13, PSR welding bracket 14, and VCU welding bracket 15, forms the installation plane for the BDU and VCU. The BMS welding bracket 16 is welded horizontally in parallel, providing a plane for the installation of the BMS. The wire harness bracket 17 is welded to the frame structure, providing a binding and fixing point for water pipes and electrical wire harnesses.

[0040] like Figure 4 As shown, the all-in-one controller is mounted on the lower side of the BDU integrated bracket via the all-in-one controller bracket 18, which improves the installation utilization of the space here, and the heat dissipation water pipe is fixed to the wire harness bracket 17.

[0041] The specific implementation process is as follows: like Figure 1-4As shown, the new energy heavy truck BDU integrated bracket system of this embodiment includes BDU integrated bracket 1, bracket connecting plate (connecting bracket one 2, connecting bracket two 3) and multiple functional installation structures.

[0042] The BDU integrated bracket 1 is a frame structure, constructed by overlapping and welding three layers of channel-shaped bent components. Specifically, it includes two lower longitudinal beams 7, two lower transverse beams 8, four middle vertical beams 9, two upper transverse beams 10, upper longitudinal beam one 11, and upper longitudinal beam two 12. The lower longitudinal beams 7 and lower transverse beams 8 are welded together to form the lower frame. The middle vertical beams 9 are vertically connected between the lower frame and the upper structure. The upper transverse beams 10, upper longitudinal beam one 11, and upper longitudinal beam two 12 are welded together to form the mounting plane.

[0043] In the functional installation structure, BDU welding bracket 13, PSR welding bracket 14 and VCU welding bracket 15 are fixed on the mounting plane for installing BDU, PSR and VCU respectively; two BMS welding brackets 16 are welded horizontally side by side in front of the BDU integrated bracket 1 for fixing BMS; a screw-connected distribution box bracket 5 is fixed on the mounting plane by 6 bolts for installing LPDU; four wire harness brackets 17 are also welded on the BDU integrated bracket 1 for bundling and fixing water pipes and electrical wire harnesses.

[0044] The BDU integrated bracket 1 is screwed to the connecting bracket 1 2 and connecting bracket 2 3 through the side mounting holes. Two suspension pads 4 are evenly arranged between the connecting bracket 1 2 and connecting bracket 2 3. The ends of the connecting bracket 1 2 and connecting bracket 2 3 away from the BDU integrated bracket 1 are fixedly connected to the vehicle frame. The height of the bracket connecting plate is adjustable to 100mm to adapt to the overall height requirements of the new energy heavy truck.

[0045] The lower side of the BDU integrated bracket 1 is equipped with a multi-function controller via a lower connecting bracket. The multi-function controller and the BDU are arranged vertically. The cooling water pipe is fixed to the wiring harness bracket 17. In addition, the steering oil tank is screwed to the BDU integrated bracket 1 via the steering oil tank bracket 6.

[0046] The effects of this embodiment are: 1. Integration effect: In this embodiment, BDU, BMS, VCU, LPDU, PSR, steering oil tank, and all-in-one controller are all centrally installed through this integrated bracket system. Compared with the traditional decentralized installation mode, the use of 6 independent brackets is reduced, the space utilization rate is increased by more than 40%, and the vehicle weight is reduced by about 8kg.

[0047] 2. Structural reliability: The lap welding design of the grooved bending parts increases the welding strength of the bracket by 30%, and the suspension pad 4 effectively buffers the vibration during vehicle operation. Tests have shown that the vibration amplitude of the components is reduced by 50%, significantly improving the service life of electrical components.

[0048] 3. Installation flexibility: By adjusting the height of the bracket connecting plate to 150mm, it can be precisely adapted to the overall layout of the new energy heavy truck without modifying the main body of the bracket, thus improving installation efficiency by 60%.

[0049] 4. Convenience of maintenance: The centralized installation design eliminates the need to disassemble multiple brackets when inspecting components, reducing maintenance time to 1 / 3 of the traditional mode; the multi-in-one controller and BDU are arranged vertically, reducing the length of high-voltage wiring harness by 2m and lowering the line failure rate by 45%.

[0050] 5. Orderliness of wiring: The wire harness bracket 17 enables the classified bundling of water pipes and electrical wire harnesses, which completely solves the problem of messy wiring and greatly reduces the difficulty of subsequent wiring maintenance.

[0051] The above descriptions are merely embodiments of this utility model. Commonly known technical solutions and / or characteristics are not described in detail here. It should be noted that those skilled in the art can make various modifications and improvements without departing from the technical solution of this utility model. These modifications and improvements should also be considered within the scope of protection of this utility model, and will not affect the effectiveness of the implementation of this utility model or the practicality of the patent. The scope of protection claimed in this application should be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.

Claims

1. A BDU integrated bracket system for new energy heavy-duty trucks, characterized in that, The system includes a BDU integrated bracket, a bracket connecting plate, and multiple functional mounting structures. The BDU integrated bracket is a frame structure that connects to the frame of a new energy heavy-duty truck via the bracket connecting plate. The functional mounting structures include a mounting plane, a welding bracket, and a screw-connected distribution box bracket. The mounting plane is used to mount the BDU and VCU, the welding bracket is used to fix the BMS and PSR, and the screw-connected distribution box bracket is used to fix the LPDU. The BDU integrated bracket is formed by overlapping and welding three layers of grooved bending parts, including a lower longitudinal beam, a lower transverse beam, a middle vertical beam, an upper transverse beam, and an upper longitudinal beam. The lower longitudinal beam and the lower transverse beam form the lower frame, and the upper transverse beam and the upper longitudinal beam form the mounting plane.

2. The new energy heavy-duty truck BDU integrated bracket system according to claim 1, characterized in that, The bracket connecting plate includes a connecting bracket one and a connecting bracket two. The BDU integrated bracket is screwed to the connecting bracket one and the connecting bracket two through side mounting holes. The ends of the connecting bracket one and the connecting bracket two away from the BDU integrated bracket are fixedly connected to the vehicle frame.

3. The new energy heavy-duty truck BDU integrated bracket system according to claim 2, characterized in that, A suspension pad is provided between the first connecting bracket and the second connecting bracket. The number of suspension pads is 2-4, and they are evenly distributed along the length direction of the first connecting bracket and the second connecting bracket.

4. The new energy heavy truck BDU integrated bracket system according to claim 1, characterized in that, The welding bracket includes a BDU welding bracket, a PSR welding bracket, a VCU welding bracket, and a BMS welding bracket; the BDU welding bracket, PSR welding bracket, and VCU welding bracket are all fixed to the mounting plane, and the BMS welding bracket is welded horizontally in parallel to the front of the BDU integrated bracket.

5. The new energy heavy-duty truck BDU integrated bracket system according to claim 1, characterized in that, The BDU integrated bracket is welded with wire harness brackets, and the number of wire harness brackets is 3-5, which are used to bundle and fix water pipes and electrical wire harnesses.

6. The new energy heavy-duty truck BDU integrated bracket system according to claim 1, characterized in that, The lower side of the BDU integrated bracket is provided with a lower connecting bracket, which is used to install the multi-in-one controller. The multi-in-one controller and the BDU are arranged vertically.

7. The new energy heavy-duty truck BDU integrated bracket system according to claim 1, characterized in that, The height of the bracket connecting plate is adjustable, with an adjustment range of 80-200mm.

8. The new energy heavy-duty truck BDU integrated bracket system according to claim 1, characterized in that, The upper longitudinal beam includes upper longitudinal beam one and upper longitudinal beam two, which are arranged in parallel. There are two upper crossbeams, which are respectively connected to the two ends of upper longitudinal beam one and upper longitudinal beam two.

9. The new energy heavy-duty truck BDU integrated bracket system according to claim 1, characterized in that, The mounting plane of the screw-in distribution box bracket and the BDU integrated bracket is fixedly connected by four bolts.

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