A battery three-in-one high-voltage system architecture
Patent Information
- Application Number
- CN202522699339.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-19
- Publication Date
- 2026-11-03
- Estimated Expiration
- 2035-12-19
AI Technical Summary
In existing high-voltage systems for new energy vehicles, each independent high-voltage component requires a separate metal casing and long high-voltage wiring harness, which increases cost and space occupation and reduces assembly efficiency.
The high-voltage system architecture adopts a three-in-one battery design, integrating the OBC module and DC/DC module into a three-in-one battery pack. Short copper busbars are used to replace long high-voltage wiring harnesses, and liquid cooling pipes are installed inside the battery pack for heat dissipation.
Reduce material and processing costs, minimize space occupation, improve assembly efficiency, and enhance electrical safety and stability.
Smart Images
Figure CN224928857U_ABST
Abstract
Description
Technical Field
[0001] This utility model belongs to the field of high-voltage system technology for new energy vehicles, and more specifically, it relates to a high-voltage system architecture that integrates three batteries. Background Technology
[0002] In the current high-voltage system of new energy vehicles, the core high-voltage components include battery pack, electronic control, motor, compressor, PTC, DC / OBC (including DC / DC module and OBC module), PDU, charging dock, etc., and each component is designed and arranged independently.
[0003] The existing technology has the following drawbacks: each independent high-voltage component requires a separate metal casing to protect the internal circuit, which increases the cost of casing materials; independent components need to be connected by high-voltage wiring harnesses and connectors of varying lengths (e.g., the battery pack needs to be connected to the PDU via a wiring harness, the PDU to the DC / OBC, and the DC / OBC to the charging socket and the 12V small battery), which results in high wiring harness costs and occupies space in the vehicle layout; the assembly of independent components needs to be performed separately, which increases the number of steps in the vehicle assembly process and reduces the assembly efficiency of the production line.
[0004] To address the aforementioned technical problems, this application proposes a solution. Utility Model Content
[0005] The technical problem to be solved by this utility model is to overcome the shortcomings of the prior art and provide a high-voltage system architecture that integrates three batteries. This utility model has the characteristics of reducing costs, reducing space, improving efficiency and enhancing safety.
[0006] The aforementioned high-voltage system architecture for a three-in-one battery is characterized by comprising a charging base, a 12V small battery, a three-in-one battery pack, a compressor, a PTC, an electronic control unit, a motor, and a PDU. The three-in-one battery pack integrates battery cells, main fuse, pre-charge contactor, pre-charge resistor, main positive contactor, OBC module, low-voltage output plug-in, high-voltage output plug-in, DC / DC module and main negative contactor. The positive terminal of the battery cell is connected in series with the main fuse and the main positive contactor, and then connected to one end of the main negative contactor. The other end of the main negative contactor forms a circuit with the negative terminal of the battery cell. The pre-charge contactor and the pre-charge resistor are connected in series and then connected in parallel to the two ends of the main positive contactor. The end of the main positive contactor furthest from the main fuse and the end of the main negative contactor furthest from the battery cell are respectively connected to the positive and negative terminals of the DC side of the OBC module via branch copper busbars. The AC side of the OBC module is connected to an AC charging connector, and the AC charging connector is detachably connected to the charging base.
[0007] Preferably, the end of the main positive contactor furthest from the main fuse and the end of the main negative contactor furthest from the battery cell are respectively connected to the positive and negative terminals of the high-voltage input side of the DC / DC module via branch copper busbars. The low-voltage output side of the DC / DC module is connected to the low-voltage output plug-in, and the low-voltage output plug-in is electrically connected to the 12V small battery. The end of the main positive contactor furthest from the main fuse and the end of the main negative contactor furthest from the battery cell are also respectively connected to the high-voltage output plug-in via lines. The high-voltage output plug-in is electrically connected to the input terminal of the PDU. The output terminal of the PDU is electrically connected to the input terminals of the compressor, PTC, and electronic control unit, respectively. The output terminal of the electronic control unit is electrically connected to the motor.
[0008] Preferably, the OBC module and the DC / DC module are arranged side by side inside the three-in-one battery pack on the side near the high-voltage output plug, and an insulating partition is provided between the OBC module, the DC / DC module and the battery cell.
[0009] Preferably, the branch copper busbar is made of copper alloy, and the outer surface of the branch copper busbar is wrapped with a high-temperature resistant insulating layer.
[0010] Preferably, the connection end between the AC charging connector and the charging base is provided with a waterproof sealing ring, and the pins of the AC charging connector are provided with an anti-accidental contact protection structure.
[0011] Preferably, the casing of the three-in-one battery pack is provided with liquid cooling pipes, and the liquid cooling pipes are arranged corresponding to the positions of the OBC module and the DC / DC module.
[0012] Compared with the prior art, the beneficial effects of this utility model are: This invention offers the following advantages: Reduced costs: It eliminates the need for separate metal casings for the OBC and DC / DC modules, and replaces long high-voltage wiring harnesses with short copper busbars, reducing material and processing costs; Reduced space: The integrated design reduces the space required for independent modules, saving installation area at the front and rear of the vehicle; Increased efficiency: It reduces assembly steps for independent DC / OBC components, simplifies production line processes, and improves overall vehicle assembly efficiency; Enhanced safety: Short copper busbar connections reduce wiring harness joints, lowering contact resistance and the risk of failure. Furthermore, insulating partitions between modules enhance electrical safety. This structure is integrated into the battery pack, utilizing the internal coolant pipes for heat dissipation, eliminating the need for externally extending coolant pipes for separate heat dissipation, thus optimizing the design and saving costs. Attached Figure Description
[0013] Figure 1 For the existing system architecture diagram Figure 2 This is a diagram of the overall system architecture of this utility model; Figure 3This is a system architecture diagram of the three-in-one battery pack of this utility model. Detailed Implementation
[0014] The present invention will be further described below with reference to the accompanying drawings: The directional terms used in the detailed description paragraphs are only for the convenience of those skilled in the art to understand the technical solutions described in this application based on the visual orientation shown in the accompanying drawings. Unless otherwise expressly specified and limited, the terms "setting," "installation," "connection," etc., should be interpreted broadly, and those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.
[0015] like Figures 2 to 3 As shown, a high-voltage system architecture for a three-in-one battery includes a charging base, a 12V small battery, a three-in-one battery pack, a compressor, a PTC, an electronic control unit, a motor, and a PDU. The three-in-one battery pack integrates battery cells, a main fuse, a pre-charge contactor, a pre-charge resistor, a main positive contactor, an OBC module, a low-voltage output module, a high-voltage output module, a DC / DC module, and a main negative contactor. The positive terminal of the battery cell is connected in series with the main fuse and the main positive contactor, then connected to one end of the main negative contactor. The other end of the main negative contactor forms a circuit with the negative terminal of the battery cell. The pre-charge contactor and the pre-charge resistor are connected in series and then in parallel across the two ends of the main positive contactor. The main fuse's function is to trip in case of a circuit malfunction, creating an open circuit and improving safety to protect other hardware.
[0016] The end of the main positive contactor furthest from the main fuse and the end of the main negative contactor furthest from the battery cell are connected to the DC positive and negative terminals of the OBC module via branch copper busbars, respectively. The AC side of the OBC module is connected to an AC charging connector, which is detachably connected to the charging socket. Using copper busbars instead of high-voltage wiring harnesses reduces resistance, minimizes power loss, and improves circuit stability.
[0017] The end of the main positive contactor furthest from the main fuse and the end of the main negative contactor furthest from the battery cell are respectively connected to the positive and negative terminals of the high-voltage input side of the DC / DC module via branch copper busbars. The low-voltage output side of the DC / DC module is connected to the low-voltage output plug-in, which is electrically connected to the 12V small battery. The end of the main positive contactor furthest from the main fuse and the end of the main negative contactor furthest from the battery cell are also respectively connected to the high-voltage output plug-in via lines. The high-voltage output plug-in is electrically connected to the input terminal of the PDU. The output terminal of the PDU is electrically connected to the input terminals of the compressor, PTC, and electronic control unit, respectively. The output terminal of the electronic control unit is electrically connected to the motor.
[0018] The OBC module and DC / DC module are arranged side-by-side inside the three-in-one battery pack, near the high-voltage output connector. Insulating partitions separate the OBC module, DC / DC module, and battery cells. The branch copper busbars are made of copper alloy, and their outer surface is covered with a high-temperature resistant insulating layer. The AC charging connector's connection point is equipped with a waterproof sealing ring to prevent water ingress and short circuits. The AC charging connector's pins also feature anti-accidental contact protection to prevent injury from incorrect contact.
[0019] The 3-in-1 battery pack has internal liquid cooling channels arranged corresponding to the locations of the OBC module and DC / DC module. The use of coolant within the battery pack enhances heat dissipation.
[0020] Workflow: During AC charging, the charging gun is inserted into the charging socket. After the OBC module detects the charging signal, it controls the main negative contactor to close, followed by the pre-charge contactor to close, pre-charging the system (to avoid large current surges, and pre-charging is required every time the main positive and main negative contactors close). After pre-charging is complete, the main positive contactor closes and the pre-charge contactor opens. The AC power flows from the charging socket to the AC charging connector, then to the OBC module for rectification into DC high voltage, and finally to the battery cell for charging. When powered by a 12V small battery, after the vehicle is powered on, the high voltage of the battery cell (e.g., 380V) is stepped down to 13.5V by the DC / DC module, then to the low-voltage output connector, and finally to 12V. The small battery supplies power to the vehicle's low-voltage system (a pre-charging process is performed before each power-on, and the main positive and main negative contactors remain closed until the vehicle is powered off or fully charged); when the vehicle is driven, the driver presses the accelerator pedal, the electronic control system starts working, and the battery begins to output current. The high-voltage electricity from the battery cell goes through the high-voltage output plug to the PDU and then to the electronic control system. The electronic control system inverts the DC power into AC power to drive the motor; at the same time, the PDU distributes power to the compressor (when the air conditioner is on) and the PTC (when the heating is on).
[0021] Finally, although this specification describes embodiments, not every embodiment contains only one independent technical solution. This way of describing the specification is only for clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.
Claims
1. A high-voltage system architecture integrating three batteries, characterized in that: Includes charging dock, 12V small battery, three-in-one battery pack, compressor, PTC, electronic control, motor and PDU; The three-in-one battery pack integrates battery cells, main fuse, pre-charge contactor, pre-charge resistor, main positive contactor, OBC module, low-voltage output plug-in, high-voltage output plug-in, DC / DC module and main negative contactor. The positive terminal of the battery cell is connected in series with the main fuse and the main positive contactor, and then connected to one end of the main negative contactor. The other end of the main negative contactor forms a circuit with the negative terminal of the battery cell. The pre-charge contactor and the pre-charge resistor are connected in series and then connected in parallel to the two ends of the main positive contactor. The end of the main positive contactor furthest from the main fuse and the end of the main negative contactor furthest from the battery cell are respectively connected to the positive and negative terminals of the DC side of the OBC module via branch copper busbars. The AC side of the OBC module is connected to an AC charging connector, and the AC charging connector is detachably connected to the charging base.
2. The high-voltage system architecture of the battery three-in-one according to claim 1, characterized in that: The end of the main positive contactor furthest from the main fuse and the end of the main negative contactor furthest from the battery cell are respectively connected to the positive and negative terminals of the high-voltage input side of the DC / DC module through branch copper busbars. The low-voltage output side of the DC / DC module is connected to the low-voltage output plug-in, and the low-voltage output plug-in is electrically connected to the 12V small battery. The end of the main positive contactor furthest from the main fuse and the end of the main negative contactor furthest from the battery cell are respectively connected to the high-voltage output plug-in via lines. The high-voltage output plug-in is electrically connected to the input terminal of the PDU. The output terminal of the PDU is electrically connected to the input terminals of the compressor, PTC, and electronic control unit respectively. The output terminal of the electronic control unit is electrically connected to the motor.
3. The high-voltage system architecture of the battery three-in-one according to claim 1, characterized in that: The OBC module and DC / DC module are arranged side by side inside the three-in-one battery pack, near the high-voltage output plug, and an insulating partition is provided between the OBC module, DC / DC module and battery cell.
4. The high-voltage system architecture of the battery three-in-one according to claim 1, characterized in that: The branch copper busbar is made of copper alloy, and its outer surface is covered with a high-temperature resistant insulating layer.
5. The high-voltage system architecture of the battery three-in-one according to claim 1, characterized in that: The AC charging connector is equipped with a waterproof sealing ring at the connection end with the charging base, and the pins of the AC charging connector are equipped with an anti-accidental contact protection structure.
6. The high-voltage system architecture of the battery three-in-one according to claim 1, characterized in that: The three-in-one battery pack has liquid cooling pipes inside its casing, and these pipes are arranged to correspond to the positions of the OBC module and the DC / DC module.