High voltage control box and energy storage system

Abstract

The application discloses a high-voltage control box and an energy storage system. The high-voltage control box comprises a control circuit and a battery management module. The control circuit comprises a fusion switch, and the fusion switch comprises a main positive switch, a pre-charging positive switch and a negative switch. The battery management module is configured to control the on-off of the pre-charging positive switch, the main positive switch and the negative switch to control the charging and discharging of a battery cluster. The application provides a high-voltage control box and an energy storage system. By using a fusion switch to replace multiple power switches scattered in the related art, the control of the charging and discharging of the battery cluster is realized, thereby saving the occupied space of the original power switch device and being conducive to the miniaturization of the high-voltage control box.

Description

Technical Field

[0001] This application relates to the field of energy storage equipment technology, and more specifically, to a high-voltage control box and an energy storage system. Background Technology

[0002] In energy storage systems, a high-voltage control box is typically used to control battery clusters. The high-voltage control box includes a control circuit, which usually includes multiple power switches to control the charging and discharging of the battery clusters. However, the power switches are relatively large, which affects the miniaturization of the high-voltage control box. Summary of the Invention

[0003] This application provides a high-voltage control box and an energy storage system to solve at least one of the aforementioned technical problems.

[0004] The high-voltage control box of this application embodiment is used to control a battery cluster. The high-voltage control box includes a control circuit and a battery management module. The control circuit includes a fusion switch, which includes a main positive switch, a pre-charge positive switch, and a negative switch. The battery management module is configured to control the on / off state of the pre-charge positive switch, the main positive switch, and the negative switch to control the charging and discharging of the battery cluster.

[0005] This application provides a high-voltage control box that uses a fused switch to replace multiple dispersed power switches in related technologies to control the charging and discharging of battery clusters, thereby saving the space occupied by the original power switch devices and facilitating the miniaturization of the high-voltage control box.

[0006] In some embodiments, the control circuit further includes: Used to connect the main positive input terminal and the main negative input terminal of the battery pack; The system includes a main positive output terminal and a main negative output terminal. The main positive input terminal is electrically connected to the main positive output terminal via the main positive switch, and the main negative input terminal is electrically connected to the main negative output terminal via the negative switch. A pre-charge resistor is electrically connected to the main positive input terminal, and the pre-charge resistor is electrically connected to the main positive output terminal through the pre-charge positive switch.

[0007] Thus, by introducing a pre-charge resistor to limit the inrush current during power-on, the control circuit is effectively protected, which helps to improve the safety and reliability of the high-voltage control box startup.

[0008] In some embodiments, the negative switch includes a main negative switch and a pre-charge negative switch. The main negative input terminal is electrically connected to the main negative output terminal through the main negative switch and the pre-charge negative switch, respectively. The main negative switch is linked with the main positive switch, and the pre-charge negative switch is linked with the pre-charge positive switch.

[0009] In this way, by further dividing the negative switch into a main negative switch that is linked with the main positive switch and a pre-charge negative switch that is linked with the pre-charge positive switch, synchronous control of the main switch and the pre-charge switch is achieved, which helps to reduce the control difficulty, avoid the potential difference problem caused by single-pole switching, and improve the safety and reliability of the system.

[0010] In some embodiments, the control circuit further includes a fuse, which includes a first fuse and a second fuse. The main positive switch and the precharge positive switch are connected to the main positive input terminal through the first fuse, and the negative switch is connected to the main negative input terminal through the second fuse.

[0011] In this way, by setting fuses at the input terminals of the main positive switch, the precharge positive switch, and the negative switch, effective overcurrent protection of the circuit is achieved, which helps to prevent damage to subsequent components when the current is abnormal.

[0012] In some embodiments, the high-voltage control box further includes a cooling fan, with the air inlet or outlet of the cooling fan facing the fuse.

[0013] In this way, by directing the airflow of the cooling fan directly at the fuse, active cooling of the fuse is achieved, which helps to reduce its temperature rise, extend its service life, and maintain the reliability of the protection function.

[0014] In some embodiments, the control circuit further includes copper busbars, which include a first positive copper busbar, a second positive copper busbar, a third positive copper busbar, a first negative copper busbar, a second negative copper busbar, and a third negative copper busbar. The main positive input terminal is connected to the first fuse through the first positive copper busbar. The first fuse is connected to the main positive switch and the pre-charge positive switch through the second positive copper busbar. The main positive switch and the pre-charge positive switch are connected to the main positive output terminal through the third positive copper busbar. The main negative input terminal is connected to the second fuse through the first negative copper busbar. The second fuse is connected to the negative switch through the second negative copper busbar. The negative switch is connected to the main negative output terminal through the third negative copper busbar.

[0015] Thus, by using a multi-segment copper busbar structure to connect the input and output terminals, heat dissipation of the control circuit is facilitated, connection impedance is reduced, electrical performance is improved, and assembly and maintenance are facilitated.

[0016] In some embodiments, the width of the first positive copper busbar is greater than the width of the second positive copper busbar and the third positive copper busbar, and the width of the first negative copper busbar is greater than the width of the second negative copper busbar and the third negative copper busbar.

[0017] In this way, by widening the width of the first positive copper busbar and the first negative copper busbar, the current carrying capacity of the high current section copper busbar is enhanced, which helps to reduce heat generation and improve system stability.

[0018] In some embodiments, the control circuit further includes a Hall sensor and a detection copper rod. The Hall sensor is electrically connected to the battery management module. The Hall sensor has a detection hole. One end of the detection copper rod is connected to the third positive copper busbar, and the other end of the detection copper rod passes through the detection hole and is connected to the main positive output terminal.

[0019] In this way, by connecting the third positive copper busbar and the main positive output terminal through the Hall sensor and the detection copper rod, accurate detection of the output current is achieved, which facilitates real-time monitoring and intelligent control by the battery management module.

[0020] In some embodiments, the high-voltage control box includes at least two control circuits, both of which are electrically connected to the battery management module, and each control circuit is used to control the charging and discharging of the corresponding battery cluster.

[0021] In this way, by using a single battery management module to control at least two control circuits simultaneously, the internal space layout of the high-voltage control box is optimized, which is conducive to further miniaturization of the high-voltage control box.

[0022] In some embodiments, the high-voltage control box further includes a housing, in which the pre-charge resistor, the fusion switch, and the battery management module are all disposed. The main positive input terminal, the main negative input terminal, the main positive output terminal, and the main negative output terminal are disposed on the side wall of the housing. The main positive input terminal and the main negative input terminal of the same control circuit are arranged close to each other and staggered, and the main positive output terminal and the main negative output terminal of the same control circuit are arranged close to each other and staggered.

[0023] In this way, by setting the main positive input terminal and the main negative input terminal close together and interleaved, and setting the main positive output terminal and the main negative output terminal close together and interleaved, operators can more easily distinguish the input terminal and the output terminal and the corresponding positive and negative terminals, which helps to reduce the difficulty of operation.

[0024] In some embodiments, the high-voltage control box further includes a handle disposed on the housing.

[0025] Thus, by setting handles on the housing, the high-voltage control box is easy to move and install, improving operational convenience and user experience.

[0026] Another embodiment of the energy storage system of this application includes at least two battery clusters and a high-voltage control box as described in any of the above claims, wherein the battery clusters are electrically connected to the control circuit.

[0027] Additional aspects and advantages of embodiments of this application will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of embodiments of this application. Attached Figure Description

[0028] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. Wherein: Figure 1 This is a circuit diagram of the control circuit of the high-voltage control box according to an embodiment of this application; Figure 2 This is a schematic diagram of the internal structure of the high-voltage control box according to an embodiment of this application; Figure 3 This is a schematic diagram of the high-voltage control box according to an embodiment of this application; Figure 4 This is a front view of the high-voltage control box according to an embodiment of this application; Figure 5 This is a schematic diagram of the internal structure of the high-voltage control box according to an embodiment of this application.

[0029] Key component symbols: High voltage control box 100, control circuit 10, fusion switch 11, main positive switch 111, precharge positive switch 112, negative switch 113, main negative switch 1131, precharge negative switch 1132, main positive input terminal 121, main negative input terminal 122, main positive output terminal 131, main negative output terminal 132, precharge resistor 14, fuse 15, first fuse 151, second fuse 152, cooling fan 16, copper busbar 17, first positive copper busbar 171, second positive copper busbar 172, third positive copper busbar 173, first negative copper busbar 174, second negative copper busbar 175, third negative copper busbar 176, Hall sensor 18, detection copper rod 19, battery management module 20, housing 30, first surface 31, handle 40. Detailed Implementation

[0030] The embodiments of this application are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this application, and should not be construed as limiting this application. In the description of this application, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as limiting this application. In the description of this application, "a plurality of" means two or more, unless otherwise explicitly specified.

[0031] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection. They can refer to a mechanical connection or an electrical connection. They can refer to a direct connection or an indirect connection through an intermediate medium, and they can refer to the internal communication of two components or the interaction between two components. For those skilled in the art, the specific meaning of the above terms in this application can be understood according to the specific circumstances.

[0032] In this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature being directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0033] This disclosure provides many different embodiments or examples for implementing different structures of this application. To simplify the disclosure, specific examples of components and arrangements are described herein. Of course, these are merely examples and are not intended to limit the scope of this application. Furthermore, reference numerals and / or letters may be repeated in different examples; such repetition is for simplification and clarity and does not in itself indicate a relationship between the various embodiments and / or arrangements discussed. In addition, various specific examples of processes and materials are provided in this application, but those skilled in the art will recognize the application of other processes and / or the use of other materials.

[0034] Please see Figure 1 This application provides an energy storage system, including at least two battery clusters and a high-voltage control box 100 of any of the above. The high-voltage control box 100 includes a control circuit 10 and a battery management module 20. The battery clusters are electrically connected to the control circuit 10. The control circuit 10 includes a fusion switch 11, which includes a main positive switch 111, a pre-charge positive switch 112, and a negative switch 113. The battery management module 20 is configured to control the on / off state of the pre-charge positive switch 112, the main positive switch 111, and the negative switch 113 to control the charging and discharging of the battery clusters.

[0035] This application provides a high-voltage control box 100, which uses a fused switch 11 to replace multiple power switches that are scattered in related technologies to control the charging and discharging of battery clusters, thereby saving the space occupied by the original power switch devices and facilitating the miniaturization of the high-voltage control box 100.

[0036] For details, please refer to Figures 1 to 4 In this embodiment of the application, the high voltage control box 100 also includes a housing 30, and the fusion switch 11 and the battery management module 20 are both disposed inside the housing 30.

[0037] In this embodiment, the integrated switch 11 can adopt an integrated packaging structure, integrating the main positive switch 111, the pre-charge positive switch 112, and the negative switch 113 within the same insulating housing 30, and achieving electrical connection through an internal bus. The housing 30 is made of high-temperature resistant epoxy resin material, capable of withstanding the heat and high-voltage environment generated during the operation of the control circuit 10. Inside the housing 30, the pins of the main positive switch 111, the pre-charge positive switch 112, and the negative switch 113 are connected by silver-plated copper sheets. The silver plating layer effectively reduces contact resistance and power loss. Thus, compared to three independently distributed power switches, the separate housing 30 for each switch and external connecting cables are eliminated, reducing the overall size of the switch assembly. Furthermore, the integrated design reduces external wiring nodes, lowers the risk of poor contact due to loose wiring, and further improves the operational reliability of the control circuit 10.

[0038] Please see Figure 1 , Figure 2 and Figure 4 In some embodiments, the control circuit 10 further includes a main positive input terminal 121, a main negative input terminal 122, a main positive output terminal 131, a main negative output terminal 132, and a pre-charge resistor 14 for connecting the battery cluster. The main positive input terminal 121 is electrically connected to the main positive output terminal 131 through a main positive switch 111, and the main negative input terminal 122 is electrically connected to the main negative output terminal 132 through a negative switch 113. The main positive input terminal 121 is electrically connected to the pre-charge resistor 14, and the pre-charge resistor 14 is electrically connected to the main positive output terminal 131 through a pre-charge positive switch 112.

[0039] Thus, by introducing a pre-charge resistor 14 to limit the inrush current during the power-on process, the control circuit 10 is effectively protected, which helps to improve the safety and reliability of the high-voltage control box 100 during startup.

[0040] Specifically, in this embodiment, the high-voltage control box 100 includes a main positive input terminal 121, a main negative input terminal 122, a main positive output terminal 131, and a main negative output terminal 132 disposed on the side wall of the housing 30. The main positive input terminal 121 and the main negative input terminal 122 are respectively used to connect to the total positive and total negative terminals of the battery cluster, while the main positive output terminal 131 and the main negative output terminal 132 are used to connect to the load.

[0041] In this embodiment of the application, the high voltage control box 100 also includes a pre-charge resistor 14 disposed in the housing 30. The pre-charge resistor 14 is a protective element of the high voltage control box 100, which is usually composed of a high-power, high-resistance resistor. Its core function is to limit the magnitude of the inrush current in the initial stage of the high voltage system being powered on, thereby protecting the core components of the high voltage system from damage caused by huge current surges.

[0042] In some embodiments, the pre-charge resistor 14 may be a power-type wire-wound resistor or a sheet resistor, the resistance value of which is calculated based on the system rated voltage and capacitive load (such as the inverter DC bus capacitor). The pre-charge resistor 14 can be fixed inside the high-voltage control box 100 by a sheet metal bracket and connected to the main positive input terminal 121 via a copper busbar 17 or a high-voltage cable.

[0043] In this embodiment, the battery management module 20 controls the charging and discharging of the battery cluster by detecting the voltage of the main positive output terminal 131 (i.e., the DC bus capacitor) and controlling the on / off state of the precharge positive switch 112, the main positive switch 111 and the negative switch 113.

[0044] Specifically, when the control circuit 10 is powered on, it first closes the pre-charge positive switch 112, allowing the current from the battery cluster to flow to the output terminal through the pre-charge resistor 14. Due to the current-limiting effect of the resistor, the current is controlled within a safe range, avoiding instantaneous high-current charging of the downstream capacitor. Only when the output voltage approaches the battery voltage does the battery management module 20 control the main positive switch 111 to close, and then open the pre-charge positive switch 112, completing the soft-start process.

[0045] In some embodiments, to enhance heat dissipation, heat dissipation fins may be added to the outer surface of the pre-charge resistor 14.

[0046] Please see Figure 1 In some embodiments, the negative switch 113 includes a main negative switch 1131 and a pre-charge negative switch 1132. The main negative input terminal 122 is electrically connected to the main negative output terminal 132 through the main negative switch 1131 and the pre-charge negative switch 1132 respectively. The main negative switch 1131 is linked with the main positive switch 111, and the pre-charge negative switch 1132 is linked with the pre-charge positive switch 112.

[0047] Thus, by further dividing the negative switch 113 into a main negative switch 1131 that is linked with the main positive switch 111 and a pre-charge negative switch 1132 that is linked with the pre-charge positive switch 112, synchronous control of the main switch and the pre-charge switch is achieved, which helps to reduce the control difficulty, avoid the potential difference problem caused by single-pole switching, and improve the safety and reliability of the system.

[0048] Specifically, in the embodiments of this application, the main negative switch 1131 and the pre-charge negative switch 1132 use the same type and specifications of high-voltage DC relays as the main positive switch 111 and the pre-charge positive switch 112, in order to adapt to the current and voltage requirements of the energy storage system.

[0049] In some embodiments, the battery management module 20 can be connected to the control coils of the main positive switch 111 and the main negative switch 1131 via the same set of control signal lines, and to the control coils of the precharge positive switch 112 and the precharge negative switch 1132 via another set of control signal lines to ensure the synchronicity of the switching actions. It should be noted that electrical synchronization should be achieved using hardware logic circuits to ensure consistent signal delays and avoid asynchrony caused by software response deviations.

[0050] In some embodiments, mechanical interlocking can also be used to link the main negative switch 1131 and the main positive switch 111. Specifically, the main positive switch 111 and the main negative switch 1131 can be integrated into a double-pole contactor, and the two pairs of contacts can be driven to operate synchronously by a common electromagnet; the same applies to the pre-charge positive and negative switches.

[0051] When the battery management module 20 receives a power-on signal, it first controls the linked pre-charge positive switch 112 and pre-charge negative switch 1132 to close, and detects the voltage between the main positive output terminal 131 and the negative terminal. When the voltage of the main positive output terminal 131 rises to a preset value (usually 90% of the battery cluster voltage), it determines that pre-charging is complete, and then controls the linked main positive switch 111 and main negative switch 1131 to close, and then controls the pre-charge positive switch 112 and pre-charge negative switch 1132 to open. The bipolar linkage design eliminates the floating ground potential that may occur when a single pole is disconnected, prevents damage to the insulation monitoring equipment due to common-mode voltage, and reduces the risk of system leakage current.

[0052] Please see Figure 1 and Figure 2 In some embodiments, the control circuit 10 further includes a fuse 15, which includes a first fuse 151 and a second fuse 152. The main positive switch 111 and the precharge positive switch 112 are connected to the main positive input terminal 121 through the first fuse 151, and the negative switch 113 is connected to the main negative input terminal 122 through the second fuse 152.

[0053] Thus, by setting fuses 15 at the input terminals of the main positive switch 111, the precharge positive switch 112, and the negative switch 113 respectively, effective overcurrent protection of the circuit is achieved, which helps to prevent damage to subsequent components when the current is abnormal.

[0054] Specifically, in this embodiment, both the first fuse 151 and the second fuse 152 are high-voltage DC fuses 15, whose rated voltage matches the operating voltage of the energy storage system. For example, for an energy storage system with an 800V operating voltage, the rated voltage of fuse 15 is selected as 1000V, and the rated current is set according to the maximum output current of the battery cluster, typically 1.2 times the maximum output current. When an abnormal situation such as a short circuit or overload occurs in the control circuit 10, such as when the main positive switch 111 sticks and the current suddenly rises to 550A, the fuse element of the first fuse 151 quickly melts, cutting off the path between the main positive input terminal 121 and subsequent switching elements, preventing excessive current from flowing into valuable components such as the main positive switch 111, the precharge positive switch 112, and the battery management module 20, thereby reducing equipment damage costs. Compared with the solution of using a circuit breaker for overcurrent protection, the fuse 15 has the advantages of faster response speed, smaller size, and lower cost, making it more suitable for application in miniaturized devices such as the high-voltage control box 100. Meanwhile, the two fuses 15 are respectively set at the input end of the positive and negative circuits, realizing independent protection for the positive and negative circuits and further improving the comprehensiveness of protection.

[0055] In some embodiments, the rated current of the first fuse 151 and the second fuse 152 is selected based on the maximum short-circuit current of the battery cluster and the system operating current. The fuse 15 can be fixed to the housing 30 or the substrate of the control circuit 10 by a bracket and fasteners to ensure good thermal conductivity and mechanical stability.

[0056] Please see Figure 2 In some embodiments, the high-voltage control box 100 also includes a cooling fan 16, with the air inlet or outlet of the cooling fan 16 facing the fuse 15.

[0057] In this way, by directing the air intake or exhaust direction of the cooling fan 16 directly towards the fuse 15, active heat dissipation of the fuse 15 is achieved, which helps to reduce its temperature rise, extend its service life, and maintain the reliability of the protection function.

[0058] Specifically, in this embodiment, the cooling fan 16 can be an axial fan or a centrifugal fan, and is installed on the housing 30 of the high-voltage control box 100 or on the substrate of the control circuit 10 to form a forced air cooling duct.

[0059] In some embodiments, the exhaust end of the cooling fan 16 may be positioned directly opposite the fuse 15, so that cold air can be blown directly onto the surface of the fuse 15, thereby enhancing convective heat transfer.

[0060] In some embodiments, the air intake of the cooling fan 16 may be positioned directly opposite the fuse 15, thereby drawing away the hot air near the fuse 15 by means of ventilation.

[0061] In some embodiments, a temperature sensor is also provided inside the high-voltage control box 100. The temperature sensor is electrically connected to the battery management module 20. The start / stop and speed of the cooling fan 16 can be adjusted by the battery management module 20 based on the signal from the temperature sensor. For example, when the temperature exceeds 60°C, the cooling fan 16 is controlled to start; when the temperature drops below 45°C, the cooling fan 16 is controlled to stop running. This intelligent start / stop control method can effectively save energy and achieve a balance between quiet operation and heat dissipation.

[0062] In some embodiments, heat dissipation fins may be added to the surface of the fuse 15 to increase the heat dissipation area.

[0063] Please see Figure 2In some embodiments, the control circuit 10 further includes a copper busbar 17, which includes a first positive copper busbar 171, a second positive copper busbar 172, a third positive copper busbar 173, a first negative copper busbar 174, a second negative copper busbar 175, and a third negative copper busbar 176. The main positive input terminal 121 is connected to a first fuse 151 through the first positive copper busbar 171. The first fuse 151 is connected to a main positive switch 111 and a pre-charge positive switch 112 through the second positive copper busbar 172. The main positive switch 111 and the pre-charge positive switch 112 are connected to the main positive output terminal 131 through the third positive copper busbar 173. The main negative input terminal 122 is connected to a second fuse 152 through the first negative copper busbar 174. The second fuse 152 is connected to a negative switch 113 through the second negative copper busbar 175. The negative switch 113 is connected to the main negative output terminal 132 through the third negative copper busbar 176.

[0064] Thus, by using a multi-segment copper busbar 17 structure to connect the path from the input end to the output end, it is easier to control the heat dissipation of the circuit 10, which helps to reduce connection impedance, improve electrical performance, and facilitate assembly and maintenance.

[0065] Specifically, in this embodiment, one end of the first positive copper busbar 171 is tightly connected to the terminal block of the main positive input terminal 121, and the other end is connected to the input terminal of the first fuse 151; one end of the second positive copper busbar 172 is connected to the output terminal of the first fuse 151, and the other end is connected to the input terminals of the main positive switch 111 and the pre-charge positive switch 112 respectively through a branch structure; the third positive copper busbar 173 combines the output terminals of the main positive switch 111 and the pre-charge positive switch 112 and connects them to the main positive output terminal 131. The copper busbar 17 is connected to each electrical component by bolts. Optionally, conductive paste can be applied to the connection points between the copper busbar 17 and each electrical component to reduce contact resistance. The connection method of the negative terminal copper busbar 17 is the same as that of the positive terminal. Compared with the scheme of using multiple cable segments, the cross-sectional area of ​​the copper busbar 17 is larger, and the heat dissipation area is also increased accordingly. When the same current is passed, the temperature rise of the copper busbar 17 is only about 1 / 3 of that of the cable, effectively reducing the overall circuit loss. Meanwhile, the copper busbar 17 has good rigidity and can serve as a support structure for circuit components, simplifying the installation layout of the control circuit 10. During maintenance, if a component needs to be replaced, only the corresponding copper busbar 17 connecting bolts need to be removed, eliminating the need to comb through the wires one by one as with cable connections, greatly improving maintenance convenience.

[0066] In some embodiments, all copper busbars 17 are made of T2 copper, which has a high conductivity of over 98% and good ductility, making it easy to process and shape. Optionally, the copper busbars 17 may undergo surface treatment to prevent oxidation and rust, ensuring conductivity during long-term use.

[0067] In some embodiments, the width of the first positive copper busbar 171 is greater than the width of the second positive copper busbar 172 and the third positive copper busbar 173, and the width of the first negative copper busbar 174 is greater than the width of the second negative copper busbar 175 and the third negative copper busbar 176.

[0068] Thus, by widening the width of the first positive copper busbar 171 and the first negative copper busbar 174, the current-carrying capacity of the high-current section copper busbar 17 is enhanced, which helps to reduce heat generation and improve system stability.

[0069] Specifically, the first positive copper busbar 171 connects the main positive input terminal 121 to the first fuse 151, and the first negative copper busbar 174 connects the main negative input terminal 122 to the second fuse 152. These two copper busbars 17 are located at the starting point of the current input of the control circuit 10, and always carry the maximum current output by the battery cluster during the charging and discharging process of the energy storage system, belonging to the high current density region. Therefore, in this embodiment, the width of the first positive copper busbar 171 and the first negative copper busbar 174 can be set to 1.5 to 2 times that of the other copper busbars 17, specifically determined according to the current density and temperature rise requirements. After widening, the same cross-sectional area can be achieved by increasing the thickness or width of the copper busbar 17, but increasing the width is more conducive to surface heat dissipation. For example, the first positive copper busbar 171 can adopt a 50mm×5mm specification, while the second positive copper busbar 172 can be 30mm×5mm.

[0070] In some embodiments, when space is limited, a multi-layer laminated copper busbar 17 can be used instead of a single-layer wide copper busbar 17, but attention must be paid to the balance between interlayer insulation and heat dissipation. The widened design reduces the resistance and heat generation per unit length, reduces voltage drop and power loss, and improves short-time overcurrent capability. A sufficient number of bolts must be ensured at the connection points to evenly distribute pressure and prevent localized overheating.

[0071] In some embodiments, the control circuit 10 further includes a Hall sensor 18 and a detection copper rod 19. The Hall sensor 18 is electrically connected to the battery management module 20. The Hall sensor 18 is provided with a detection hole. One end of the detection copper rod 19 is connected to the third positive copper busbar 173, and the other end of the detection copper rod 19 passes through the detection hole and is connected to the main positive output terminal 131.

[0072] In this way, by using Hall sensor 18 and detection copper rod 19 to connect the third positive copper busbar 173 and the main positive output terminal 131, accurate detection of output current is achieved, which facilitates real-time monitoring and intelligent control by battery management module 20.

[0073] Specifically, in this embodiment, the Hall sensor 18 can be an open-type or closed-type DC sensor. The detection copper rod 19 is a straight copper rod, and its diameter matches the detection aperture of the Hall sensor 18. Both ends of the detection copper rod 19 are fixed to the third positive copper busbar 173 and the main positive output terminal 131, respectively, with the middle section passing through the sensor's detection aperture. When current flows through the detection copper rod 19, the Hall sensor 18 outputs a voltage signal proportional to the current. This signal is transmitted to the battery management module 20 via a shielded cable. The battery management module 20 can calculate the actual output current value based on this signal and determine whether the current is abnormal.

[0074] Please see Figure 2 and Figure 5 In some embodiments, the high-voltage control box 100 includes at least two control circuits 10, both of which are electrically connected to the battery management module 20. Each control circuit 10 is used to control the charging and discharging of the corresponding battery cluster.

[0075] In this way, by using a battery management module 20 to control at least two control circuits 10 simultaneously, the internal space layout of the high voltage control box 100 is optimized, which is conducive to further miniaturization of the high voltage control box 100.

[0076] In this embodiment of the application, multiple control circuits 10 can be arranged horizontally or vertically side by side in the high voltage control box 100. Specifically, the high voltage control box 100 includes two control circuits 10 arranged vertically side by side in the high voltage control box 100. A partition is provided inside the housing 30. One control circuit 10 is located at the bottom of the housing 30, and the other is located on the partition.

[0077] In this embodiment, at least two control circuits 10 share the same battery management module 20. The battery management module 20 typically possesses multi-channel acquisition and control capabilities, such as multiple ADCs detecting the current and voltage of each battery cluster, and multiple digital outputs controlling each fusion switch 11. The input terminals of each control circuit 10 are connected to an independent battery cluster, and their output terminals are connected in parallel to a common DC bus. The battery management module 20 can manage the pre-charge, charge / discharge, and disconnection operations of each cluster through polling or synchronization, and can achieve inter-cluster equalization control.

[0078] Please see Figure 4 In some embodiments, the main positive input terminal 121 and the main negative input terminal 122 of the same control circuit 10 are arranged close to each other and alternately, and the main positive output terminal 131 and the main negative output terminal 132 of the same control circuit 10 are arranged close to each other and alternately.

[0079] Thus, by placing the main positive input terminal 121 and the main negative input terminal 122 close together and interleaving them, and placing the main positive output terminal 131 and the main negative output terminal 132 close together and interleaving them, operators can more easily distinguish the input terminals and output terminals and their corresponding positive and negative poles, which helps to reduce the difficulty of operation.

[0080] Specifically, in this embodiment, the high-voltage control box 100 is rectangular. The main positive input terminal 121, the main negative input terminal 122, the main positive output terminal 131, and the main negative output terminal 132 are all located on the same side wall of the high-voltage control box 100. To facilitate wiring by operators and to distinguish between the main positive input terminal 121, the main negative input terminal 122, the main positive output terminal 131, and the main negative output terminal 132, thereby preventing mis-insertion, the input and output terminals are respectively located at opposite ends of the same side wall, and the positive and negative poles are distinguished by numerical height. For example, the main positive input terminal 121 and the main negative input terminal 122 are located at a height of... On the right side of the first surface 31 of the high voltage control box 100, the main positive output terminal 131 and the main negative output terminal 132 are located on the left side of the first surface 31 of the high voltage control box 100. The main positive input terminal 121 and the main positive output terminal 131 are at the same vertical height, and the main negative input terminal 122 and the main negative output terminal 132 are at the same vertical height but greater than the main positive input terminal 121 and the main positive output terminal 131. This ensures that terminals at the same height have the same polarity and that terminals on the same side have the same current direction, making it easier for the operator to distinguish them and also better matching the output position of the battery pack.

[0081] In this embodiment, the high-voltage control box 100 has two sets of control circuits 10. The main positive input terminal 121, main negative input terminal 122, main positive output terminal 131, and main negative output terminal 132 of the two sets of control circuits 10 can be distinguished by height. Specifically, the main positive input terminal 121, main negative input terminal 122, main positive output terminal 131, and main negative output terminal 132 of the first set of control circuits 10 are located at the top of the first surface 31 of the control box, while the other set is located at the bottom. Furthermore, the same terminals of the different control circuits 10 are located in the same vertical direction, which is beneficial for further differentiation. For example, the main positive input terminal 121 of the first set and the main positive input terminal 121 of the second set are located in the same vertical direction, and the main negative input terminal 122 of the first set and the main negative input terminal 122 of the second set are located in the same vertical direction and to the left of the main positive input terminal 121.

[0082] In some embodiments, the main positive input terminal 121, main negative input terminal 122, main positive output terminal 131 and main negative output terminal 132 can also be distinguished by means of color and adding labels, thereby preventing misinsertion.

[0083] Please see Figure 3 In some embodiments, the high-voltage control box 100 also includes a handle 40 disposed on the housing 30.

[0084] Thus, by providing a handle 40 on the housing 30, the high-voltage control box 100 is easy to move and install, improving operational convenience and user experience.

[0085] Specifically, in this embodiment, the handle 40 can be a bent metal handle or a molded plastic handle, and is fixed to the sides or top of the housing 30 by bolts. The metal handle 40 must be fitted with an insulating sleeve to prevent accidental electric shock. The handle 40 must be ergonomically designed, providing sufficient gripping space and strength, and its load-bearing capacity should exceed twice the weight of the control box itself.

[0086] In some embodiments, for heavier models of the high-voltage control box 100, four handles 40 can be provided for multiple people to lift or for mechanical assistance to use. The handles 40 should be installed away from heat dissipation ducts and wiring areas to avoid affecting normal operation. In addition, the handles 40 can also be used as lifting points, but the rated lifting capacity must be clearly marked.

[0087] In the description of this specification, the references to "certain embodiments," "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples" refer to specific features, structures, materials, or characteristics described in connection with the described embodiment or example, which are included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0088] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of the stated features. In the description of this application, "multiple" means at least two, such as two or three, unless otherwise explicitly specified.

[0089] Although embodiments of this application have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting this application. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of this application, the scope of which is defined by the claims and their equivalents.

Claims

1. A high-voltage control box for controlling a battery cluster, characterized in that, The high-voltage control box includes a control circuit and a battery management module. The control circuit includes a fusion switch, which includes a main positive switch, a pre-charge positive switch, and a negative switch. The battery management module is configured to control the on / off state of the pre-charge positive switch, the main positive switch, and the negative switch to control the charging and discharging of the battery cluster.

2. The high-voltage control box according to claim 1, characterized in that, The control circuit also includes: Used to connect the main positive input terminal and the main negative input terminal of the battery pack; The system includes a main positive output terminal and a main negative output terminal. The main positive input terminal is electrically connected to the main positive output terminal via the main positive switch, and the main negative input terminal is electrically connected to the main negative output terminal via the negative switch. A pre-charge resistor is electrically connected to the main positive input terminal, and the pre-charge resistor is electrically connected to the main positive output terminal through the pre-charge positive switch.

3. The high-voltage control box according to claim 2, characterized in that, The negative switch includes a main negative switch and a pre-charge negative switch. The main negative input terminal is electrically connected to the main negative output terminal through the main negative switch and the pre-charge negative switch, respectively. The main negative switch is linked with the main positive switch, and the pre-charge negative switch is linked with the pre-charge positive switch.

4. The high-voltage control box according to claim 2, characterized in that, The control circuit also includes a fuse, which includes a first fuse and a second fuse. The main positive switch and the precharge positive switch are connected to the main positive input terminal through the first fuse, and the negative switch is connected to the main negative input terminal through the second fuse.

5. The high-voltage control box according to claim 4, characterized in that, The high-voltage control box also includes a cooling fan, with the air inlet or outlet of the cooling fan facing the fuse.

6. The high-voltage control box according to claim 4, characterized in that, The control circuit further includes copper busbars, which include a first positive copper busbar, a second positive copper busbar, a third positive copper busbar, a first negative copper busbar, a second negative copper busbar, and a third negative copper busbar. The main positive input terminal is connected to the first fuse through the first positive copper busbar. The first fuse is connected to the main positive switch and the pre-charge positive switch through the second positive copper busbar. The main positive switch and the pre-charge positive switch are connected to the main positive output terminal through the third positive copper busbar. The main negative input terminal is connected to the second fuse through the first negative copper busbar. The second fuse is connected to the negative switch through the second negative copper busbar. The negative switch is connected to the main negative output terminal through the third negative copper busbar.

7. The high-voltage control box according to claim 6, characterized in that, The width of the first positive copper busbar is greater than the width of the second positive copper busbar and the third positive copper busbar, and the width of the first negative copper busbar is greater than the width of the second negative copper busbar and the third negative copper busbar.

8. The high-voltage control box according to claim 6, characterized in that, The control circuit also includes a Hall sensor and a detection copper rod. The Hall sensor is electrically connected to the battery management module. The Hall sensor has a detection hole. One end of the detection copper rod is connected to the third positive copper busbar, and the other end of the detection copper rod passes through the detection hole and is connected to the main positive output terminal.

9. The high-voltage control box according to claim 2, characterized in that, The high-voltage control box includes at least two control circuits, both of which are electrically connected to the battery management module. Each control circuit is used to control the charging and discharging of the corresponding battery cluster.

10. The high-voltage control box according to claim 2, characterized in that, The high-voltage control box also includes a housing, in which the pre-charge resistor, the fusion switch, and the battery management module are all disposed. The main positive input terminal, the main negative input terminal, the main positive output terminal, and the main negative output terminal are disposed on the side wall of the housing. The main positive input terminal and the main negative input terminal of the same control circuit are arranged close to each other and staggered, and the main positive output terminal and the main negative output terminal of the same control circuit are arranged close to each other and staggered.

11. The high-voltage control box according to claim 10, characterized in that, The high-voltage control box also includes a handle, which is disposed on the housing.

12. An energy storage system, characterized in that, It includes at least two battery clusters and a high-voltage control box as described in any one of claims 1-11, wherein the battery clusters are electrically connected to the control circuit.

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