An integrated power device

Abstract

The utility model relates to new energy automobile technical field provides an integrated power supply unit, including the casing, and set up in the first inverter, second inverter, converter and high voltage distribution box of casing, the control circuit board and precharge resistance are set up in the casing, the high voltage cable connector of the multiple head formula of high voltage distribution box electric connection is set up on the one outside of casing, the high voltage connector connector of converter electric connection is set up on the other outside of casing. Through the layout design of optimization internal component, the first inverter, second inverter, converter, relay, fuse, control circuit board and precharge resistance etc. are arranged compactly in three-dimensional in the casing, effectively improve the space utilization, reduce the overall volume and weight, simultaneously, through setting up film capacitor and connecting between insulated gate bipolar transistor and precharge resistance, strengthen the electrical stability of system, improve the power density and operation reliability of integrated power supply unit.

Description

Technical Field

[0001] This utility model relates to the technical field of new energy vehicles, specifically to an integrated power supply device. Background Technology

[0002] On-board power supplies (OBCs) are core components of new energy vehicles. They are primarily responsible for converting the electrical energy from the power battery into voltage and current suitable for vehicle use, and also for providing stable power support to the vehicle's internal electrical equipment. The OBC, DC / DC converter, and PDU within an on-board power supply can be individual components or integrated into a system, thus featuring an all-in-one design to improve overall efficiency.

[0003] However, due to layout design issues, existing all-in-one integrated power devices are often large or heavy. Utility Model Content

[0004] The purpose of this invention is to provide an integrated power supply device, which aims to improve the problem of existing integrated power supply devices being too large or too heavy.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] An integrated power supply device includes a housing, and a first inverter for DC-to-AC conversion, a second inverter for DC-to-AC conversion, a converter for DC-to-DC conversion, and a high-voltage distribution box disposed within the housing. The first inverter, the second inverter, and the converter are electrically connected to the high-voltage distribution box.

[0007] The housing is provided with a plurality of support columns for supporting and installing the first inverter and the second inverter. The converter is arranged side by side with the first inverter or the second inverter. The high voltage distribution box is located above or to one side of the first inverter and / or the second inverter and / or the converter.

[0008] The housing contains a control circuit board and a pre-charging resistor arranged side by side with the high-voltage distribution box. The control circuit board and the pre-charging resistor are electrically connected to the high-voltage distribution box.

[0009] A multi-head high-voltage cable connector electrically connected to the high-voltage distribution box is provided on one outer side of the housing, and a high-voltage plug-in connector electrically connected to the converter is provided on the other outer side of the housing.

[0010] Preferably, an insulation detector is also provided inside the housing, and the insulation detector is electrically connected between the control circuit board and the pre-charge resistor.

[0011] Preferably, the high-voltage distribution box includes multiple sets of electrically connected first relays and first fuses, and multiple sets of electrically connected second relays and second fuses, with the multiple sets of first relays and first fuses arranged side by side on a fixed plate;

[0012] The second fuse is electrically connected to one end of the high-voltage cable connector, and multiple sets of first relays and second relays are connected in series and electrically connected to one end of the high-voltage cable connector.

[0013] Preferably, the high-voltage distribution box is further provided with multiple sets of electrically connected third relays and third fuses, and the multiple sets of third relays and third fuses are electrically connected between the pre-charge resistor and the high-voltage cable joint;

[0014] Alternatively, it may include an insulated gate bipolar transistor, wherein the high-voltage cable connector is provided with a three-phase copper busbar connector, and the insulated gate bipolar transistor is electrically connected between the precharge resistor and the three-phase copper busbar connector.

[0015] Preferably, a maintenance switch is provided on one outer side of the housing, and the maintenance switch is electrically connected between the second fuse and the high-voltage cable connector.

[0016] Preferably, it also includes a current sensor, which is disposed in the middle of the housing and divides the internal space of the housing into a left placement space and a right placement space;

[0017] The first inverter, the second inverter, and the converter are disposed on the left placement space, and the fixing plate is disposed above the first inverter and / or the second inverter and / or the converter;

[0018] The third relay and the third fuse or the insulated gate bipolar transistor are disposed in the right placement space, and the control circuit board is disposed above the third relay and the third fuse or the insulated gate bipolar transistor;

[0019] The pre-charge resistor is arranged side by side with the control circuit board, or the pre-charge resistor is arranged side by side with the third relay and the third fuse or the insulated gate bipolar transistor.

[0020] Preferably, it also includes a thin-film capacitor, which is electrically connected between the insulated gate bipolar transistor and the pre-charge resistor.

[0021] Preferably, the control circuit board includes a relay control board and a main drive control board.

[0022] Preferably, the top surface of the housing is provided with an opening and a cover plate for closing or opening the opening.

[0023] Preferably, the first inverter is an inverter for a steering controller, and the second inverter is an inverter for an air compressor controller.

[0024] By adopting the above technical solution, this utility model has the following advantages compared with the prior art:

[0025] This utility model optimizes the layout design of internal components, arranging the first inverter, second inverter, converter, relay, fuse, control circuit board, and pre-charge resistor in a compact three-dimensional arrangement within the housing, effectively improving space utilization and reducing overall size and weight. Simultaneously, by incorporating a thin-film capacitor connected between the insulated-gate bipolar transistor and the pre-charge resistor, the electrical stability of the system is enhanced, improving the power density and operational reliability of the integrated power supply device. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the integrated power supply device described in this utility model;

[0027] Figure 2 This is a schematic diagram of the integrated power supply device with a maintenance switch described in this utility model;

[0028] Figure 3 This is a schematic diagram of the internal layout of the integrated power supply device described in this utility model;

[0029] Figure 4 This is a schematic diagram of the internal layout of the integrated power supply device with a current sensor according to the present invention;

[0030] Figure 5 This is a partial view of the integrated power supply device described in this utility model;

[0031] Figure 6 This is a schematic diagram of the housing of the integrated power supply device described in this utility model.

[0032] Explanation of reference numerals in the attached figures:

[0033] 10. Housing; 101. First inverter; 102. Second inverter; 103. Converter;

[0034] 104. High-voltage distribution box; 105. Support column; 106. Control circuit board; 107. Pre-charge resistor;

[0035] 108. High-voltage cable connector; 109. High-voltage plug-in connector; 110. Insulation tester;

[0036] 111. Maintenance switch; 112. Cover plate;

[0037] 1041. First relay; 1042. First fuse; 1043. Second relay;

[0038] 1044. Second fuse; 1045. Third relay; 1046. Third fuse;

[0039] 1061. Relay control board; 1062. Main drive control board;

[0040] 1081. Three-phase copper busbar connector;

[0041] 20. Insulated Gate Bipolar Transistor; 30. Current Sensor; 40. Thin Film Capacitor. Detailed Implementation

[0042] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain this utility model and are not intended to limit this utility model.

[0043] Additionally, it should be noted that the terms "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer" are all based on the orientation or positional relationship shown in the accompanying drawings. They are merely for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element of this utility model must have a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0044] When an element is referred to as being "fixed to," "set on," or "contained on" another element, it can be directly on or indirectly on that other element. When an element is referred to as being "connected to," it can be directly connected to or indirectly connected to that other element.

[0045] Unless otherwise expressly 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; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0046] Example

[0047] The fuses mentioned below can be AE73400i38, EV325-4GL32A, AGK2320L18 or RS309-MF-S400A, the current sensors can be BLF500-S7T / SP4 or BLF700-S7T / SP4, and the film capacitors can be MKP-DC-LC or DC-Link 2000 series.

[0048] Please refer to Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5 and Figure 6 As shown, this embodiment provides an integrated power supply device, including a housing 10, and a first inverter 101 for DC-to-AC conversion, a second inverter 102 for DC-to-AC conversion, a converter 103 for DC-to-DC conversion, and a high-voltage distribution box 104 disposed within the housing 10. The first inverter 101, the second inverter 102, and the converter 103 are electrically connected to the high-voltage distribution box 104. The housing 10 is provided with multiple support columns 105 for supporting and mounting the first inverter 101 and the second inverter 102. The converter 103 is connected in parallel with either the first inverter 101 or the second inverter 102. The high-voltage distribution box 104 is positioned above or to one side of the first inverter 101 and / or the second inverter 102 and / or the converter 103. Inside the housing 10, a control circuit board 106 and a pre-charging resistor 107 are arranged side-by-side with the high-voltage distribution box 104, and the control circuit board 106 and the pre-charging resistor 107 are electrically connected to the high-voltage distribution box 104. A multi-head high-voltage cable connector 108 electrically connected to the high-voltage distribution box 104 is provided on one outer side of the housing 10, and a high-voltage plug-in connector 109 electrically connected to the converter 103 is provided on the other outer side of the housing 10.

[0049] The integrated power supply unit of this embodiment effectively improves space utilization and reduces assembly complexity by highly integrating multiple core power conversion modules within the same housing 10. The rational layout of the high-voltage distribution box 104 with the inverter and converter 103, combined with the stable support of the support column 105 for key components, enhances the overall structural reliability. The control circuit board 106 and the pre-charge resistor 107 are positioned adjacent to the high-voltage distribution box 104 (the pre-charge resistor 107 is a resistor used during the power supply voltage rise process; its main function is to limit the charging current and prevent instantaneous large currents during the initial charging of the capacitor, thereby protecting circuit components), shortening the high-voltage circuit path and helping to reduce interference and energy loss. The multi-head high-voltage cable connector 108 and the high-voltage plug-in connector 109 are located on opposite sides of the housing 10, facilitating on-site wiring and quick connection, and effectively isolating high and low voltage areas, improving safety performance. All power modules share the housing 10 and some electrical interfaces, achieving standardized design, which is beneficial for mass production and later maintenance. The overall structure is compact and suitable for applications in new energy vehicles and industrial equipment with high requirements for power density and operational stability.

[0050] Furthermore, the housing 10 of the integrated power supply unit is made of high-strength aluminum alloy, possessing excellent heat dissipation performance and electromagnetic shielding effect. The surface is anodized to enhance corrosion resistance and insulation performance. The bottom of the housing 10 is designed with heat dissipation fins or a grid groove structure, allowing for close contact with an external heat dissipation system, further improving heat transfer efficiency and ensuring stable operation of internal components under high load conditions. The first inverter 101 is the inverter for the steering controller, and the second inverter 102 is the inverter for the air compressor controller.

[0051] Specifically, the interior of the housing 10 features a partitioned layout. Heat-generating units such as the inverter and converter 103 are supported and fixed by support columns 105, forming a heat dissipation space or channel between them and the housing 10. This facilitates heat dissipation and circulation, allowing for efficient heat dissipation through air convection, external air cooling, or water cooling systems. Alternatively, the converter 103 can be fitted tightly to the base plate of the housing 10 using thermal pads or related materials, enabling rapid heat transfer to the outside. Furthermore, the side-by-side arrangement of the inverter and converter 103 not only saves space but also facilitates operation, allowing for corresponding interface areas on the same side of the housing 10 for convenient centralized wiring and maintenance.

[0052] The area above the inverter and converter 103 can be used to install a high-voltage distribution box 104, facilitating short-distance connections between the high-voltage distribution box 104 and each power module, further reducing voltage drop and electromagnetic interference risks. An insulating layer is installed below the high-voltage distribution box 104, allowing it to be mounted on an insulating board, forming a double-layer structure with the inverter and converter 103. This effectively prevents high-voltage interference with the low-voltage control circuitry.

[0053] like Figure 4 As shown, the control circuit board 106 in this embodiment includes a relay control board 1061 and a main drive control board 1062. The control circuit board 106 is arranged close to the high-voltage distribution box 104, reducing signal delay and noise through short-distance connection and improving system response accuracy. An insulating guide groove and shielding cover (which can be designed separately or separated on the housing 10) are provided between the control circuit board 106 and the high-voltage distribution box 104 to further block the coupling interference of high-voltage transients to low-voltage signals. Furthermore, a pre-charge resistor 107 is located below the control circuit board 106, facilitating the formation of a pre-charge circuit with the main contactor in the high-voltage distribution box 104 via a short path, effectively suppressing surge current at power-on. Thus, a four-region layout design with two layers (upper and lower) and two parts (left and right) is formed within the housing 10, achieving physical separation and functional integration of the power unit and control unit. This ensures safety under high-voltage, high-current operation and improves the overall reliability and response efficiency of the system. The modules are connected through standardized interfaces, which facilitates assembly and troubleshooting, while also reserving space for future functional expansion.

[0054] Correspondingly, the multi-head high-voltage cable connector 108 can be installed on the side where it can be conveniently accessed from all four areas, facilitating centralized access and reliable connection of high-voltage lines, and reducing the complexity of internal wiring layout and the risk of electromagnetic interference. Meanwhile, the high-voltage cable connector 108 is installed in a separate metal box, which is then mounted on the side of the housing 10. Electrical connection is achieved through a through-hole to the high-voltage distribution box 104 inside the housing 10. A sealing ring is provided between the metal box and the housing 10 to ensure waterproof and dustproof performance, while also achieving safe isolation for high-voltage connections.

[0055] In this embodiment, an insulation detector 110 is also provided inside the housing 10. The insulation detector 110 is electrically connected between the control circuit board 106 and the pre-charge resistor 107. The insulation detector 110 can ensure that there is no risk of leakage between the internal electrical components and the housing, thereby improving the safety of use.

[0056] like Figure 2 and Figure 3 As shown, the high-voltage distribution box 104 in this embodiment includes multiple sets of electrically connected first relays 1041 and first fuses 1042, as well as multiple sets of electrically connected second relays 1043 and second fuses 1044. The multiple sets of first relays 1041 and first fuses 1042 are arranged side by side on a fixed plate; a second fuse 1044 is electrically connected to a connector of a high-voltage cable connector 108; the multiple sets of first relays 1041 and second relays 1043 are connected in series and electrically connected to a connector of a high-voltage cable connector 108.

[0057] Specifically, the design employs relays and fuses to create a dual-protection circuit disconnection mechanism, ensuring rapid disconnection of the high-voltage circuit in the event of abnormal current or voltage surges, preventing equipment damage and safety accidents. Simultaneously, the first relay 1041 and the second relay 1043 can be connected in series, disconnecting the circuit cascadingly in the event of a fault in the main circuit, avoiding protection blind spots caused by single-contact failure. The fuse, as a passive protection element, melts immediately upon overcurrent, cutting off the circuit; the relays actively respond to system anomalies via control signals. The combined operation of these two components significantly improves protection reliability.

[0058] Furthermore, power supply can be tiered according to load importance, with critical circuits redundantly configured with dual relays and dual fuses, while non-critical circuits use a single set of protection, optimizing space utilization and cost control.

[0059] like Figure 3 and Figure 4 As shown, the high-voltage distribution box 104 in this embodiment is also provided with multiple sets of electrically connected third relays 1045 and third fuses 1046, which are electrically connected between the pre-charge resistor 107 and the high-voltage cable connector 108; or, it also includes an insulated gate bipolar transistor 20, the high-voltage cable connector 108 is provided with a three-phase copper busbar connector 1081, and the insulated gate bipolar transistor 20 is electrically connected between the pre-charge resistor 107 and the three-phase copper busbar connector 1081.

[0060] The Insulated Gate Bipolar Transistor 20 (IGBT) is a three-terminal semiconductor switching device that combines the advantages of MOSFETs and bipolar transistors. It is used in electronic devices that require high-efficiency and fast switching, such as those that can affect the power release speed and energy efficiency of electric vehicles.

[0061] When used, if an insulated-gate bipolar transistor 20 is employed, it possesses fast response characteristics, completing on / off control within microseconds, effectively supporting precise energy management of the power supply unit. By integrating this device, the system can improve power conversion efficiency; while the combination of relays and fuses provides active protection under abnormal conditions such as overload and short circuit, constructing a multi-layered safety mechanism.

[0062] like Figure 2 and Figure 4As shown, a service switch 111 is provided on one outer side of the housing 10 in this embodiment. The service switch 111 is electrically connected between the second fuse 1044 and the high-voltage cable connector 108. The service switch 111 is a manual maintenance switch, also known as a service disconnect switch. It is used to protect the safety of technicians repairing electric vehicles in high-voltage environments or to respond to emergencies. It can quickly disconnect the high-voltage circuit, ensuring a safer working environment for repairs, such as in the case of external short circuits. The service switch 111 is typically integrated into the high-voltage power distribution system and connected in series with the main power circuit. When disconnected, it completely isolates the electrical connection between the power battery and other high-voltage components.

[0063] like Figure 4 and Figure 5 As shown, this embodiment also includes a current sensor 30, which can be an SKT-HD series current sensor. The current sensor 30 is located in the middle of the housing 10, dividing the internal space of the housing 10 into a left placement space and a right placement space. The first inverter 101, the second inverter 102, and the converter 103 are located in the left placement space, and the fixing plate is located above the first inverter 101 and / or the second inverter 102 and / or the converter 103. The third relay 1045 and the third fuse 1046 or the insulated gate bipolar transistor 20 are located in the right placement space, and the control circuit board 106 is located above the third relay 1045 and the third fuse 1046 or the insulated gate bipolar transistor 20. The pre-charge resistor 107 is arranged side by side with the control circuit board 106, or the pre-charge resistor 107 is arranged side by side with the third relay 1045 and the third fuse 1046 or the insulated gate bipolar transistor 20.

[0064] As described above, the circuits and control unit on both sides are connected via a current sensor 30, enabling real-time monitoring and feedback of the system current. This layout optimizes the energy flow path within the power supply unit, reduces line redundancy and electromagnetic interference, and improves system response speed and stability. The current sensor 30 transmits the acquired signal to the control circuit board 106 in real time, working in conjunction with the insulated gate bipolar transistor 20 to achieve precise on / off control, ensuring that the pre-charge resistor 107 effectively suppresses inrush current during startup, further guaranteeing the safe and reliable operation of the high-voltage system.

[0065] like Figure 5As shown, this embodiment also includes a film capacitor 40, which is electrically connected between the insulated gate bipolar transistor 20 and the pre-charge resistor 107. The film capacitor 40 is a capacitor constructed by overlapping metal foil as electrodes with a plastic film such as polyethylene, polypropylene, polystyrene, or polycarbonate from both ends and then winding it into a cylindrical shape. It has advantages such as non-polarity, high insulation resistance, excellent frequency characteristics (wide frequency response), and very low dielectric loss, which can improve circuit transmission efficiency and reduce signal distortion, making it suitable for critical circuit scenarios such as high-frequency filtering, coupling, and bypassing. Due to its stable dielectric properties and low temperature coefficient, it can maintain the accuracy of the capacitance value in complex environments, further improving the overall reliability of electronic equipment.

[0066] like Figure 1 and Figure 2 As shown, the top surface of the housing 10 in this embodiment is provided with an opening and a cover plate 112 for closing or opening the opening. The housing 10 can be opened through the cover plate 112 to facilitate the inspection and maintenance of internal components, while ensuring structural sealing and electromagnetic shielding performance. To improve the stability and safety of equipment operation, the cover plate 112 is designed with a double fixing method of buckles and screws, or is connected by welding, to ensure that it can remain firmly sealed under vibration or impact environments, effectively preventing the intrusion of dust, moisture and conductive particles.

[0067] The above description is merely a preferred embodiment of this utility model, but the protection scope of this utility model is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this utility model should be included within the protection scope of this utility model. Therefore, the protection scope of this utility model should be determined by the scope of the claims.

Claims

1. An integrated power supply device, characterized in that, It includes a housing, and a first inverter for DC-to-AC conversion, a second inverter for DC-to-AC conversion, a converter for DC-to-DC conversion, and a high-voltage distribution box disposed within the housing. The first inverter, the second inverter, and the converter are electrically connected to the high-voltage distribution box. The housing is provided with a plurality of support columns for supporting and installing the first inverter and the second inverter. The converter is arranged side by side with the first inverter or the second inverter. The high voltage distribution box is located above or to one side of the first inverter and / or the second inverter and / or the converter. The housing contains a control circuit board and a pre-charging resistor arranged side by side with the high-voltage distribution box. The control circuit board and the pre-charging resistor are electrically connected to the high-voltage distribution box. A multi-head high-voltage cable connector electrically connected to the high-voltage distribution box is provided on one outer side of the housing, and a high-voltage plug-in connector electrically connected to the converter is provided on the other outer side of the housing.

2. The integrated power supply device according to claim 1, characterized in that: An insulation detector is also installed inside the housing, and the insulation detector is electrically connected between the control circuit board and the pre-charge resistor.

3. The integrated power supply device according to claim 1, characterized in that: The high-voltage distribution box includes multiple sets of electrically connected first relays and first fuses, as well as multiple sets of electrically connected second relays and second fuses, with multiple sets of first relays and first fuses arranged side by side on a fixed plate. The second fuse is electrically connected to one end of the high-voltage cable connector, and multiple sets of first relays and second relays are connected in series and electrically connected to one end of the high-voltage cable connector.

4. The integrated power supply device according to claim 3, characterized in that: The high-voltage distribution box is also equipped with multiple sets of electrically connected third relays and third fuses, which are electrically connected between the pre-charge resistor and the high-voltage cable joint. Alternatively, it may include an insulated gate bipolar transistor, wherein the high-voltage cable connector is provided with a three-phase copper busbar connector, and the insulated gate bipolar transistor is electrically connected between the precharge resistor and the three-phase copper busbar connector.

5. The integrated power supply device according to claim 4, characterized in that: A maintenance switch is provided on one outer side of the housing, and the maintenance switch is electrically connected between the second fuse and the high-voltage cable connector.

6. The integrated power supply device according to claim 5, characterized in that: It also includes a current sensor, which is disposed in the middle of the housing and divides the internal space of the housing into a left placement space and a right placement space; The first inverter, the second inverter, and the converter are disposed on the left placement space, and the fixing plate is disposed above the first inverter and / or the second inverter and / or the converter; The third relay and the third fuse or the insulated gate bipolar transistor are disposed in the right placement space, and the control circuit board is disposed above the third relay and the third fuse or the insulated gate bipolar transistor; The pre-charge resistor is arranged side by side with the control circuit board, or the pre-charge resistor is arranged side by side with the third relay and the third fuse or the insulated gate bipolar transistor.

7. The integrated power supply device according to claim 6, characterized in that: It also includes a thin-film capacitor electrically connected between the insulated gate bipolar transistor and the pre-charge resistor.

8. The integrated power supply device according to claim 1, characterized in that: The control circuit board includes a relay control board and a main drive control board.

9. The integrated power supply device according to claim 1, characterized in that: The top surface of the housing is provided with an opening and a cover plate for closing or opening the opening.

10. The integrated power supply device according to claim 1, characterized in that: The first inverter is the inverter for the steering controller, and the second inverter is the inverter for the air compressor controller.

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