Multi-branch high-voltage distribution box

Abstract

The utility model relates to new energy automobile technical field discloses a kind of multi-branch high-voltage distribution box, comprising: box and lid, the box is closed with the lid of top connection, form protective space after closing, the side of the box is evenly provided with battery positive connector, the inside one side of the box is evenly fixed and installed with total positive copper bar, the inside both ends of the box are provided with busbar, and the outer surface of the box is symmetrically and evenly provided with positive and negative charging connector;The positive and negative charging connector is connected with positive and negative charging copper bar in the inside one side of the box, the utility model can solve the problem of "power joule heat" caused by heavy truck, bus and other commercial vehicles in megawatt fast charging station high-power charging and when steep discharge of ramp full load starting.

Description

Technical Field

[0001] This utility model relates to the field of new energy vehicle technology, specifically to a multi-branch high-voltage distribution box. Background Technology

[0002] In the field of commercial vehicles such as pure electric heavy-duty trucks and buses, the high-voltage power distribution link of the power battery system faces two major technological challenges, both of which stem from the "power Joule heating" problem, which has become a key bottleneck restricting the high-power charging efficiency and the safety of vehicles operating under extreme conditions: First, there's the issue of high heat generation in megawatt-level fast charging scenarios. Commercial vehicles rely on megawatt-level fast charging stations for rapid energy replenishment to meet operational efficiency requirements. During charging, the input power is extremely high, and the high-voltage power distribution circuit (including cables, contactors, fuses, and other components) generates a significant amount of heat due to the "power Joule heating" effect. If this heat cannot dissipate in time, it will cause significant energy loss, leading to a substantial decrease in charging efficiency and extending the actual replenishment time. Furthermore, sustained high temperatures will accelerate the aging of power distribution components, even causing insulation melting and contact erosion, shortening component lifespan and potentially triggering thermal runaway, threatening the safety of the battery system and the entire vehicle.

[0003] Secondly, there is the issue of intense discharge and high heat during hill starts under full load. When commercial vehicles start on a slope under full load, they need to output a large current to the drive system to overcome the enormous resistance. At this time, the power battery system enters a state of intense discharge, and the high-voltage power distribution branch needs to bear a current load far exceeding that of normal operating conditions. This also causes heat to accumulate rapidly due to the "power Joule heating" effect. This high heat will continuously impact the connection nodes and insulation structure of the power distribution circuit, increasing the probability of faults such as contactor adhesion and cable short circuits, seriously affecting the vehicle's operational stability and safety under complex road conditions. Therefore, innovative technical solutions are urgently needed to overcome this core bottleneck. Utility Model Content

[0004] The purpose of this utility model is to provide a multi-branch high-voltage distribution box to solve the following technical problems: how to solve the "power Joule heating" problem caused by heavy trucks, buses and other commercial vehicles charging at high power in megawatt-level fast charging stations and violently discharging when starting fully loaded on a slope.

[0005] The purpose of this utility model can be achieved through the following technical solution: a multi-branch high-voltage distribution box, including: a box body and a box cover, wherein the box body and the top box cover can be closed and connected to form a protective space after being closed, battery positive connectors are evenly arranged on the side of the box body, a total positive copper busbar is evenly fixedly installed on one side of the inside of the box body, busbars are arranged at both ends of the inside of the box body, and positive and negative charging connectors are symmetrically and evenly arranged on the outer surface of the box body. The positive and negative charging connector is connected to positive and negative charging copper busbars on one side inside the housing. A charging relay and a discharging relay are provided between the positive and negative charging copper busbars and the busbar. Positive and negative output copper busbars are evenly arranged at both ends on the opposite side of the main positive copper busbar inside the housing. Positive and negative main circuit connectors are symmetrically arranged at both ends of the side of the enclosure and at the edge of the positive and negative charging connectors. A main negative fuse is connected to one end of the positive and negative charging copper busbar inside the enclosure. As a preferred embodiment of this utility model: a battery management system is fixedly installed on one end face inside the box, and a bracket is evenly arranged on the edge of the box away from the battery management system. A total negative copper busbar and a Hall sensor are evenly arranged on the bottom surface of one end inside the box and fixedly connected to the bracket. A main positive fuse connected to the busbar is arranged at one end of the total positive copper busbar inside the box. A maintenance switch is arranged on the side of the box and at the upper edge of the battery positive connector. A pressure relief valve for balancing internal air pressure is installed in the middle of one side of the outer surface of the box, and low-pressure communication interfaces are evenly arranged on one side of the outer surface of the box at the edge of the pressure relief valve. Insulators are uniformly fixed inside the enclosure. Thermal management connectors are uniformly arranged on the outer surface of the enclosure and in the middle of the side opposite to the pressure relief valve. A fast charging positive relay is provided at the bottom of the busbar between the main negative copper busbar and the positive and negative output copper busbars.

[0006] As a preferred embodiment of this utility model: battery negative connectors are evenly arranged on both ends of the outer surface of the housing opposite to the thermal management connector. There are six channels for each of the battery positive connector and battery negative connector, and four channels for each of the charging positive and charging negative terminals, which can support the parallel use of six battery systems and simultaneous charging of four channels.

[0007] As a preferred embodiment of this utility model: the battery management system is set up with a connector inside the housing to avoid wiring harness conversion, and the Hall sensor is used to detect the current signal and transmit the data to the battery management system.

[0008] As a preferred embodiment of this utility model: the other end of the main positive fuse is connected to the charging relay and the discharging relay via a busbar; the positive and negative charging connector is connected to one end of the main negative fuse via positive and negative charging copper busbars; the main negative fuse is connected to the end of the charging relay and the discharging relay via the positive and negative charging copper busbars; and the positive and negative output copper busbars are connected in parallel with the busbars at both ends inside the housing.

[0009] As a preferred embodiment of this utility model: the battery positive connector, battery negative connector, low-voltage communication interface, positive and negative main circuit connector, positive and negative charging connector and thermal management connector are connected to the main negative copper busbar, positive and negative output copper busbar, positive and negative charging copper busbar and main positive copper busbar inside the housing by plugging or screw fixing.

[0010] As a preferred embodiment of this utility model: the insulator has the function of isolating the positive and negative output copper busbars and the positive and negative charging copper busbars from the main negative fuse, and the insulator is made of epoxy resin insulating material.

[0011] As a preferred embodiment of this utility model: mounting feet are evenly provided on the bottom of both sides of the box, and grounding bolts are provided on the side of the box and at the lower edge of the pressure relief valve.

[0012] The beneficial effects of this utility model are: (1) In scenarios where commercial vehicles rely on megawatt-level fast charging stations for rapid energy replenishment, this utility model can effectively solve the problem of high heat generated by "power Joule heating" in high-voltage power distribution circuits, including components such as cables, contactors, and fuses, by coordinating the operation of maintenance switches, main positive fuses, charging relays, positive and negative output copper busbars, and total negative copper busbars. It can achieve dual core values. On the one hand, heat can be dissipated in a timely and efficient manner, significantly reducing power loss and improving charging efficiency. The actual energy replenishment time is effectively shortened, perfectly meeting the core needs of commercial vehicles for operational efficiency and helping vehicles achieve high-frequency and high-efficiency operation and turnover. On the other hand, efficient thermal management can prevent power distribution components from being in a continuous high-temperature environment, effectively slowing down the aging speed of components and completely eliminating the occurrence of faults such as component insulation melting and contact erosion. It can not only significantly extend the service life of components and reduce the later maintenance costs of vehicles, but also fundamentally eliminate the risk of thermal runaway, providing a solid guarantee for the safety of the battery system and the whole vehicle. (2) This utility model addresses the situation where, when a commercial vehicle starts fully loaded on a slope, the power battery system needs to output a large current to the drive system to overcome huge resistance, resulting in the high-voltage power distribution branch bearing a current load far exceeding that of conventional operating conditions. When the high heat caused by "power Joule heating" occurs, it can be effectively solved by the coordinated operation of the maintenance switch, the main positive fuse, the charging relay, the positive and negative output copper busbars and the total negative copper busbar. This will provide key protection for the operation of the vehicle in complex road conditions. First, the power distribution circuit will no longer experience rapid heat accumulation. The connection nodes and insulation structure will be protected from high heat shock. The probability of faults such as contactor sticking and cable short circuits will be greatly reduced, ensuring that the vehicle can still maintain stable power output and circuit operation under the extreme condition of starting fully loaded on a slope. Second, the reduction of circuit fault risk directly improves the stability and safety of the vehicle in complex road conditions, reduces traffic accidents caused by circuit problems, and provides strong support for the personal safety of the driver, the safety of vehicle property and road traffic safety, further expanding the applicable scenarios and operating scope of pure electric commercial vehicles. Attached Figure Description

[0013] The present invention will be further described below with reference to the accompanying drawings.

[0014] Figure 1 A schematic diagram of the three-dimensional exploded structure of a multi-branch high-voltage distribution box; Figure 2 This is a schematic diagram of the top structure of a multi-branch high-voltage distribution box; Figure 3 This is a schematic diagram of the side structure of a multi-branch high-voltage distribution box.

[0015] Figure Descriptions: 01. Enclosure; 02. Enclosure Cover; 03. Grounding Bolt; 04. Pressure Relief Valve; 05. Battery Management System; 06. Insulator; 07. Bracket; 09. Enclosure Mounting Feet; 11. Battery Positive Connector; 21. Maintenance Switch; 31. Battery Negative Connector; 41. Low-Voltage Communication Interface; 51. Positive and Negative Main Circuit Connector; 61. Positive and Negative Charging Connector; 71. Thermal Management Connector; 81. Main Negative Copper Busbar; 91. Battery Positive Copper Busbar; 301. Positive and Negative Output Copper Busbar; 401. Positive and Negative Charging Copper Busbar; 101. Hall Sensor; 201. Main Positive Fuse; 501. Main Negative Fuse; 601. Busbar; 701. Charging Relay; 709. Discharging Relay; 711. Fast Charging Positive Relay. Detailed Implementation

[0016] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of the present utility model.

[0017] Please see Figures 1-3 As shown, this utility model includes: a multi-branch high-voltage distribution box, including: a box body 01 and a box cover 02. The box body 01 and the top box cover 02 can be closed and connected to form a protective space after closing. Battery positive connectors 11 are evenly arranged on the side of the box body 01. A total positive copper busbar 91 is evenly fixedly installed on one side of the inside of the box body 01. Busbars 601 are provided at both ends of the inside of the box body 01. Positive and negative charging connectors 61 are symmetrically and evenly arranged on the outer surface of the box body 01. The positive and negative charging connector 61 is connected to a positive and negative charging copper bus 401 on one side of the inside of the housing 01. A charging relay 701 and a discharging relay 709 are provided between the positive and negative charging copper bus 401 and the bus 601. Positive and negative output copper bus 301 are evenly arranged at both ends of the housing 01, located on the opposite side of the total positive copper bus 91. Positive and negative main circuit connectors 51 are symmetrically arranged on both sides of the housing 01 and at the edge of the positive and negative charging connectors 61. Positive and negative charging copper busbars 401 are connected to a main negative fuse 501 at one end inside the housing 01. A battery management system 05 is fixedly installed on one end face inside the housing 01. A bracket 07 is evenly arranged on the edge of the housing 01 away from the battery management system 05. A total negative copper busbar 81 and a Hall sensor 101 are evenly arranged on the bottom surface of one end inside the housing 01 and are fixedly connected to the bracket 07. A main positive fuse 201 connected to the busbar 601 is arranged at one end of the total positive copper busbar 91 inside the housing 01. A maintenance switch 21 is arranged on the side of the housing 01 and at the upper edge of the battery positive connector 11. A pressure relief valve 04 for balancing internal air pressure is installed in the middle of one side of the outer surface of the housing 01. Low-pressure communication interfaces 41 are evenly arranged on one side of the outer surface of the housing 01 at the edge of the pressure relief valve 04. Insulators 06 are evenly fixedly installed inside the enclosure 01. Thermal management connectors 71 are evenly arranged on the outer surface of the enclosure 01 and in the middle of the side opposite to the pressure relief valve 04. A fast charging positive relay 711 is provided at the bottom of the busbar 601 between the total negative copper busbar 81 and the positive and negative output copper busbars 301.

[0018] On the outer surface of the housing 01, on the opposite side of the thermal management connector 71, there are battery negative connectors 31 evenly arranged at both ends. There are six channels for each of the battery positive connector 11 and battery negative connector 31, and four channels for each of the charging positive and charging negative terminals. It can support the parallel use of six battery systems and the simultaneous charging of four channels.

[0019] The battery management system 05 is installed inside the housing 01 using a connector connection method to avoid wiring harness conversion. The Hall sensor 101 is used to detect current signals and transmit data to the battery management system 05.

[0020] The other end of the main positive fuse 201 is connected to the charging relay 701 and the discharging relay 709 via the busbar 601. The positive and negative charging connector 61 is connected to one end of the main negative fuse 501 via the positive and negative charging copper busbar 401. The end of the main negative fuse 501 connected to the charging relay 701 and the discharging relay 709 via the positive and negative charging copper busbar 401 is connected. The positive and negative output copper busbar 301 is connected in parallel with the busbar 601 at both ends inside the housing 01.

[0021] Battery positive connector 11, battery negative connector 31, low-voltage communication interface 41, positive and negative main circuit connector 51, positive and negative charging connector 61 and thermal management connector 71 are connected to the main negative copper busbar 81, positive and negative output copper busbar 301, positive and negative charging copper busbar 401 and main positive copper busbar 91 inside the housing 01 by plugging or screw fixing.

[0022] Insulator 06 serves to isolate the positive and negative output copper busbars 301 and 401 and the main negative fuse 501. Insulator 06 is made of epoxy resin insulating material.

[0023] The bottom of both sides of the enclosure 01 is evenly provided with enclosure mounting feet 09, and the side of the enclosure 01 and the lower edge of the pressure relief valve 04 are provided with grounding bolts 03.

[0024] The working principle of this utility model is as follows: When a vehicle is connected to a megawatt-level fast charging station for charging, the external charging equipment receives electrical energy through the four positive and negative charging connectors 61 on the outer surface of the housing 01. The electrical energy is transmitted through the positive and negative charging copper busbars 401. At this time, the battery management system 05 receives the charging command transmitted by the low-voltage communication interface 41 and controls the charging relay 701 and the fast charging positive relay 711 to close. At the same time, the main negative fuse 501 is in the conducting state to ensure circuit safety. The electrical energy is split through the busbar 601 to the six main positive copper busbars 91 and 81, and then through the six battery positive connectors 11 and 31. The current is transmitted to six parallel battery systems, enabling simultaneous multi-channel charging. During this process, Hall sensor 101 detects the circuit current signal in real time and feeds it back to battery management system 05. If an overload occurs, the main positive fuse 201 or the main negative fuse 501 will quickly melt and cut off the circuit to prevent overheating damage. At the same time, the pressure relief valve 04 balances the pressure generated by the slight heat generated during charging. Insulator 06, made of epoxy resin, isolates the positive and negative output copper busbars 301, positive and negative charging copper busbars 401, and fuses to prevent leakage and heat conduction interference. When the vehicle starts fully loaded on a slope and enters a state of violent discharge, the battery system... A large current is output from the positive battery connector 11 and the negative battery connector 31, and converges to the busbar 601 via the main positive copper busbar 91 and the main negative copper busbar 81. The battery management system 05 controls the discharge relay 709 to close according to drive requirements. The current is then transmitted through the positive and negative output copper busbars 301 to the positive and negative main circuit connector 51, ultimately supplying the drive system. At this time, the Hall sensor 101 continuously monitors the discharge current. If the current exceeds the safety threshold, the main positive fuse 201 or the main negative fuse 501 immediately trips to cut off the circuit, preventing the accumulation of "power Joule heat" that could cause contactor sticking or cable short circuits. Simultaneously, the thermal management connector 71 can... The external thermal management system helps to remove the heat generated by the high current discharge inside the box, further suppressing high temperature. The maintenance switch 21 can manually cut off the main circuit during routine maintenance. The grounding bolt 03 ensures the grounding safety of the box. The bracket 07 fixes the main negative copper busbar 81 and the Hall sensor 101 to ensure the stability of the circuit structure. The protective space formed by the closed box cover 02 and the box body 01 avoids the interference of the external environment on the internal components. The whole system solves the "power Joule heating" problem in two scenarios through the coordinated mechanism of "multi-path current shunting to reduce load, real-time monitoring to control current, fuse + thermal management to prevent overheating, and insulation grounding to ensure safety".

[0025] The above description details one embodiment of the present utility model, but it is merely a preferred embodiment and should not be construed as limiting the scope of the present utility model. All equivalent variations and improvements made within the scope of the present utility model application should still fall within the patent coverage of the present utility model.

Claims

1. A multi-branch high-voltage distribution box, comprising: The enclosure (01) and the cover (02) are connected in a closed manner to form a protective space. The enclosure (01) and the cover (02) are characterized in that the positive battery connector (11) is uniformly arranged on the side of the enclosure (01), the positive copper busbar (91) is uniformly fixedly installed on one side of the interior of the enclosure (01), the busbar (601) is provided at both ends of the interior of the enclosure (01), and the positive and negative charging connectors (61) are symmetrically and uniformly arranged on the outer surface of the enclosure (01). The positive and negative charging connector (61) is connected to a positive and negative charging copper busbar (401) on one side inside the housing (01). A charging relay (701) and a discharging relay (709) are provided between the positive and negative charging copper busbar (401) and the busbar (601). Positive and negative output copper busbars (301) are evenly arranged at both ends of the housing (01) on the opposite side of the main positive copper busbar (91). Positive and negative main circuit connectors (51) are symmetrically arranged on both sides of the housing (01) and at the edge of the positive and negative charging connectors (61). The positive and negative charging copper busbars (401) are connected to a main and negative fuse (501) at one end inside the housing (01).

2. The multi-branch high-voltage distribution box according to claim 1, characterized in that, A battery management system (05) is fixedly installed on one end face inside the housing (01). A bracket (07) is evenly arranged on the edge of the housing (01) away from the battery management system (05). A total negative copper busbar (81) and a Hall sensor (101) are evenly arranged on the bottom surface of one end inside the housing (01) and are fixedly connected to the bracket (07). A main positive fuse (201) connected to the busbar (601) is arranged at one end of the total positive copper busbar (91) inside the housing (01). A maintenance switch (21) is arranged on the side of the housing (01) and at the upper edge of the battery positive connector (11). A pressure relief valve (04) for balancing the internal air pressure is installed in the middle of one side of the outer surface of the box (01), and low-pressure communication interfaces (41) are evenly arranged on the outer surface of one side of the box (01) at the edge of the pressure relief valve (04). Insulators (06) are uniformly fixed inside the housing (01). Thermal management connectors (71) are uniformly arranged on the outer surface of the housing (01) and in the middle of the side opposite to the pressure relief valve (04). A fast charging positive relay (711) is arranged at the bottom of the busbar (601) between the total negative copper busbar (81) and the positive and negative output copper busbars (301).

3. A multi-branch high-voltage distribution box according to claim 2, characterized in that, The outer surface of the housing (01) is provided with battery negative connectors (31) evenly arranged on both ends of the opposite side of the thermal management connector (71). The battery positive connector (11) and the battery negative connector (31) each have six channels, and the charging positive electrode and the charging negative electrode each have four channels.

4. A multi-branch high-voltage distribution box according to claim 3, characterized in that, The battery management system (05) is installed inside the housing (01) using a connector connection method to avoid wiring harness transfer. The Hall sensor (101) is used to detect current signals and transmit data to the battery management system (05).

5. A multi-branch high-voltage distribution box according to claim 4, characterized in that, The other end of the main positive fuse (201) is connected to the charging relay (701) and the discharging relay (709) through the busbar (601). The positive and negative charging connector (61) is connected to one end of the main negative fuse (501) through the positive and negative charging copper busbar (401). The end of the main negative fuse (501) connected to the charging relay (701) and the discharging relay (709) through the positive and negative charging copper busbar (401) is connected. The positive and negative output copper busbar (301) is connected in parallel with the busbar (601) at both ends inside the housing (01).

6. A multi-branch high-voltage distribution box according to claim 5, characterized in that, The battery positive connector (11), battery negative connector (31), low-voltage communication interface (41), positive and negative main circuit connector (51), positive and negative charging connector (61) and thermal management connector (71) are connected to the total negative copper busbar (81), positive and negative output copper busbar (301), positive and negative charging copper busbar (401) and total positive copper busbar (91) inside the housing (01) by plugging or screw fixing.

7. A multi-branch high-voltage distribution box according to claim 6, characterized in that, The insulator (06) has the function of isolating the positive and negative output copper busbars (301) and the positive and negative charging copper busbars (401) from the main negative fuse (501). The insulator (06) is made of epoxy resin insulating material.

8. A multi-branch high-voltage distribution box according to claim 7, characterized in that, The bottom of both sides of the box (01) is evenly provided with box mounting feet (09), and the side of the box (01) and the lower edge of the pressure relief valve (04) are provided with grounding bolts (03).

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