Power distribution unit and vehicle

Abstract

The present application provides a power distribution unit and a vehicle. The power distribution unit comprises a housing, a BMS assembly, and a wire harness assembly. The housing comprises a cover and a bottom wall that are arranged in a first direction. A first mounting cavity and a second mounting cavity that are arranged in the first direction are formed between the cover and the bottom wall; the BMS assembly is mounted in the first mounting cavity, and in a second direction, a wiring space is formed between one side of the BMS assembly and the housing; and the wire harness assembly passes through the wiring space to connect the BMS assembly and a current-carrying assembly.

Description

High-voltage power distribution units and vehicles

[0001] This application claims priority to Chinese Patent Application No. 202411946525.4, filed with the Chinese Patent Office on December 26, 2024, the entire contents of which are incorporated herein by reference. Technical Field

[0002] This application relates to the field of energy storage technology, specifically to a high-voltage power distribution unit and vehicle. Background Technology

[0003] Automobiles contain numerous electrical and electronic systems, such as engine control systems, lighting systems, infotainment systems, and safety systems. The power distribution unit (PDU) is responsible for rationally distributing the power output from the vehicle's battery or alternator to these systems and devices, ensuring a stable power supply. For example, it can provide a sufficiently large current path for the high-power-demand starter motor, while also providing a stable, low-current supply to low-power sensors.

[0004] In related technologies, a large number of electrical components in a high-voltage power distribution unit are connected using a large number of wire harnesses, with the wiring running around the perimeter of the high-voltage power distribution unit enclosure. Invention Overview

[0005] However, this setup results in complicated and messy wiring that takes up a lot of space.

[0006] This application provides a high-voltage power distribution unit. The high-voltage power distribution unit includes:

[0007] The housing includes a cover and a bottom wall arranged along a first direction, and a first mounting cavity and a second mounting cavity are formed between the cover and the bottom wall, and the first mounting cavity and the second mounting cavity are arranged along the first direction;

[0008] The BMS component is installed in the first mounting cavity. Along the second direction, a wiring space is formed between one side of the BMS component and the housing. The second direction is perpendicular to the first direction. The BMS component is electrically connected to the battery pack and external electrical equipment respectively.

[0009] A current-carrying assembly, installed in the second mounting cavity, includes a battery-side module and a load-side module electrically connected to each other. The battery-side module is electrically connected to the battery pack, and the load-side module is electrically connected to external electrical equipment.

[0010] The wiring harness assembly passes through the wiring space to connect the BMS component connections and the overcurrent components.

[0011] This application also provides a vehicle. The vehicle includes the high-voltage power distribution unit as described above. Beneficial effects

[0012] The high-voltage power distribution unit provided in this application divides the internal space of the housing into two chambers arranged along a first direction: a first mounting chamber and a second mounting chamber. The BMS (Body Management System) assembly and the overcurrent assembly are positioned in the first and second mounting chambers, respectively. This fully utilizes the space in the first direction of the high-voltage power distribution unit, resulting in shorter wiring distances and a more compact unit. The wiring harness assembly passes through the wiring space, connecting the BMS assembly and the overcurrent assembly. Within the second mounting chamber, the wiring of the wiring harness assembly is concentrated in the wiring space, resulting in a neat and compact wiring harness structure within the housing, occupying less space and facilitating operation and organization by the operator.

[0013] The vehicle provided in this application includes a high-voltage power distribution unit as described above. The internal structure of the high-voltage power distribution unit is compact, which allows the high-voltage power distribution unit to have a small volume. Attached Figure Description

[0014] Figure 1 is a three-dimensional schematic diagram of a high-voltage power distribution unit provided by a possible implementation of this application.

[0015] Figure 2 is a possible implementation of the exploded view of the high-voltage power distribution unit in Figure 1.

[0016] Figure 3 is a second possible implementation of the exploded view of the high-voltage power distribution unit in Figure 1.

[0017] Figure 4 is a cross-sectional view of the high-voltage power distribution unit in Figure 1.

[0018] Figure 5 is a magnified view of part A in Figure 4.

[0019] Figure 6 is a magnified view of part B in Figure 4.

[0020] Figure 7 is a magnified view of point C in Figure 4.

[0021] Figure 8 is a magnified view of part D in Figure 4.

[0022] Explanation of reference numerals in the attached figures:

[0023] 100. Housing; 110. Cover; 130. Bottom wall; 120. First mounting cavity; 140. Second mounting cavity; 150. Wiring space; 160. First side wall; 170. Second side wall; 180. Crossbeam; 190. Partition; 101. Third side wall; 103. Fourth side wall; 104. First chamber; 181. First part; 182. Second part; 183. Third part; 184. First side; 185. Second side; 190. Partition;

[0024] 200, First connector; 210, First connecting end; 230, Second connecting end;

[0025] 300. BMS components; 305. Fasteners; 303. BMS brackets;

[0026] 400. Second connector;

[0027] 500. Overcurrent assembly; 501. Relay; 503. TBOX signal box; 504. Conductor bus; 505. Through hole; 510. Battery-side module; 530. Load-side module;

[0028] 600, Insulating post; 601, Slot; 603, First mating part;

[0029] 700. Wiring harness assembly;

[0030] 810. Mounting base; 811. Support part; 812. Second chamber; 813. Second mating part; 820. Locking element;

[0031] 900, Hall effect sensor. Embodiments of the present invention

[0032] Automobiles contain numerous electrical and electronic systems, such as engine control systems, lighting systems, infotainment systems, and safety systems. The Power Distribution Unit (PDU) is responsible for rationally distributing the power output from the vehicle's battery pack to various systems and devices (such as electric motors, air conditioning compressors, and charging systems), ensuring a stable power supply. For example, it can provide a sufficiently large current path for the high-power-demand starter motor while also providing a stable small current supply for low-power sensors. In emergencies, the PDU can quickly cut off power to ensure occupant safety. The PDU can also communicate with the vehicle's control system (such as the Battery Management System) to share data on power usage and fault information. The PDU may also include CAN (Controller Area Network) or other forms of data bus interfaces for communication with other vehicle systems. In electric vehicles, the PDU typically sits between the high-voltage battery and the main loads, acting as a bridge to ensure the safe and efficient delivery of power to where it is needed.

[0033] In related technologies, a large number of electrical components in high-voltage power distribution units are connected using a large number of wire harnesses, which run around the perimeter of the high-voltage power distribution unit enclosure, resulting in complicated and messy wiring that occupies a large amount of space.

[0034] To overcome at least some of the aforementioned deficiencies, in a first aspect, this application provides a high-voltage power distribution unit. Referring to Figure 1, the high-voltage power distribution unit includes a housing 100, in which other components, such as a BMS assembly and an overcurrent assembly, are installed.

[0035] Referring to Figure 2, in some embodiments, the high-voltage power distribution unit further includes a BMS component 300 and an overcurrent component 500. The overcurrent component 500 can be electrically connected to external electrical equipment. The BMS component 300 is electrically connected to the battery pack and is mainly capable of monitoring and managing the operating status of the battery pack. The BMS component 300 is also electrically connected to the external electrical equipment and can communicate with it. In some examples, when the external electrical equipment includes another BMS, the BMS component 300 in this application can communicate with the BMS in the external electrical equipment. In some examples, the BMS component can provide the high-voltage power distribution unit with real-time power output capability information of the battery pack according to the vehicle's driving needs (such as acceleration, deceleration, cruising, and other different operating conditions). The overcurrent component rationally distributes the power of the battery pack to the external electrical equipment.

[0036] In some embodiments, the high-voltage power distribution unit in this application is electrically connected to the battery pack in the vehicle. External electrical devices can be various electrical systems of the vehicle, such as drive motors, air conditioning systems, and on-board electronic devices, thereby enabling the power from the battery pack to be rationally distributed to the external electrical devices.

[0037] In some embodiments, the high-voltage power distribution unit in this application can serve as a slave high-voltage power distribution unit, and can be electrically connected to the battery pack in the vehicle. External electrical equipment can serve as a master high-voltage power distribution unit, which is equipped with a battery management system (BMS). The high-voltage power distribution unit in this application is electrically connected to the master high-voltage power distribution unit, and the BMS component 300 in this application communicates with the BMS in the master high-voltage power distribution unit, thereby exchanging information. The master high-voltage power distribution unit is connected to various systems and devices in the vehicle, thereby rationally distributing the power output from the battery pack to these systems and devices, such as drive motors, air conditioning systems, and on-board electronic devices.

[0038] Referring to Figure 4, the housing 100 may include a cover 110 and a bottom wall 130 arranged along a first direction. A first mounting cavity 120 and a second mounting cavity 140 are formed between the cover 110 and the bottom wall 130, and the first mounting cavity 120 and the second mounting cavity 140 are arranged along the first direction. Referring to Figure 3, the BMS component 300 can be installed in the first mounting cavity 120, and the flow-through component 500 can be installed in the second mounting cavity 140. Thus, the flow-through component 500 and the BMS component 300 are arranged in layers along the first direction in the housing 100.

[0039] The overcurrent assembly 500 is configured to be electrically connected to both the battery pack and an external electrical device. The overcurrent assembly 500 may include a battery-side module 510 and a load-side module 530 electrically connected to each other. The battery-side module is configured to be electrically connected to the battery pack, and the load-side module is configured to be electrically connected to the external electrical device. In some examples, the battery-side module 510 may include a Hall sensor 900, and the load-side module 530 may include a relay 501, specifically including a positive relay and a negative relay.

[0040] In some examples, the battery pack may include a positive interface and a negative interface. The positive interface of the battery pack is electrically connected to a positive relay. The high-voltage power distribution unit in this application may also include a battery swapping connector, with the positive relay electrically connected to the battery swapping connector. The negative interface of the battery pack is electrically connected in sequence to a Hall sensor and a negative relay, which is then electrically connected to the battery swapping connector. The positive and negative relays can control the on / off state of the high-voltage circuit. The positive and negative relays can connect or disconnect current when the system requires it, protecting the circuit from overload or short circuit.

[0041] Hall sensors, also known as Hall effect sensors, are primarily used for current detection. A Hall effect sensor is a current measurement tool based on the Hall effect—when current flows through a conductor, a magnetic field is generated around the conductor; when a semiconductor material (such as a Hall element) placed in this magnetic field is excited by a current perpendicular to the magnetic field, a voltage is generated in a direction perpendicular to both the current and the magnetic field. This phenomenon is the Hall effect. Hall sensors can detect the current intensity passing through the PDU in real time, enabling monitoring of the battery's state of charge and discharge, calculation of remaining charge (SOC), and fault diagnosis. When abnormal current (such as overcurrent or short circuit) is detected, the Hall sensor can quickly feed back to the control system, which can then take appropriate protective measures, such as cutting off the power supply to prevent damage to the battery pack or other electrical components.

[0042] Referring to Figure 3, a wiring space 150 can be formed between one side of the BMS component 300 and the housing 100 along the second direction, which is perpendicular to the first direction. Referring to Figure 3, the high-voltage power distribution unit also includes a wiring harness assembly 700. One end of the wiring harness assembly 700 is connected to the overcurrent assembly 500, and the other end passes through the wiring space 150 and connects to the BMS component 300. In other words, the wiring harness assembly 700 passes through the wiring space, thereby connecting the BMS component 300 and the overcurrent assembly 500.

[0043] Figure 3 illustrates the three directions of the high-voltage power distribution unit, specifically the first direction, the second direction, and the third direction. The first direction can also be referred to as the height direction of the high-voltage power distribution unit, the second direction as the width direction of the high-voltage power distribution unit, and the third direction as the length direction of the high-voltage power distribution unit.

[0044] In related technologies, high-voltage power distribution units typically house a large number of electrical components on the same floor, occupying significant space in both the length and width directions. This results in cramped space in the second direction (width) and the third direction (length), while the space in the first direction (height) remains underutilized. Furthermore, the distance between electrical components at both ends is considerable, requiring long wiring distances and causing inconvenience for operators.

[0045] In this embodiment, the internal space of the housing 100 is divided into two chambers arranged along a first direction (height direction), namely the first mounting chamber 120 and the second mounting chamber 140. The BMS component 300 and the current-carrying component 500 are disposed in the second mounting chamber 140 and the first mounting chamber 120 along the first direction. This fully utilizes the space in the height direction of the high-voltage power distribution unit, resulting in shorter wiring distances and a more compact high-voltage power distribution unit. Furthermore, in this embodiment, the wiring harness assembly 700 passes through the wiring space, thereby connecting the BMS component 300 and the current-carrying component 500. Within the first mounting chamber 120, the wiring of the wiring harness assembly is relatively concentrated, with a neat and compact structure, occupying less space and facilitating operation and organization by the operator.

[0046] Referring to Figure 4, in some embodiments, the second mounting cavity 140 is located near the cover 110, and the current-carrying component 500 is installed in the second mounting cavity 140, meaning the current-carrying component 500 is located near the cover 110. The high-voltage power distribution unit also includes a first connector 200 installed on the cover 110. The first connector 200 can connect external electrical equipment and the current-carrying component 500, and the current-carrying component 500 is connected to the external electrical equipment through the first connector 200. The first connector 200 may include a first connecting end 210 and a second connecting end 230 connected together. The first connecting end 210 is located in the second mounting cavity 140 and is electrically connected to the current-carrying component 500. The second connecting end 230 is located on the side of the cover 110 away from the bottom wall 130 to facilitate connection with external electrical equipment. The first connecting end 210 and the second connecting end 230 can be integrally formed, or they can be connected by screws, riveting, or other methods.

[0047] In these embodiments, the overcurrent assembly 500 is installed in the second mounting cavity 140 and is located on the side close to the first connector 200, which reduces the connection distance between the overcurrent assembly 500 and the first connector 200, making the internal structure of the high-voltage power distribution unit more compact.

[0048] In some embodiments, the housing 100 further includes a first sidewall 160 and a second sidewall 170 disposed along a second direction (width direction). Referring to Figure 2, the housing 100 also includes a crossbeam 180 and a partition 190 disposed between the cover 110 and the bottom wall 130. The crossbeam 180 can reinforce the high-voltage power distribution unit and support and mount the partition 190. The opposite ends of the crossbeam 180 can be fixed to the first sidewall 160 and the second sidewall 170 respectively. The partition 190 is fixed to the side of the crossbeam 180 near the cover 110, and the partition 190 and the cover 110 form a second mounting cavity 140. The current-carrying assembly 500 is mounted on the side of the partition 190 facing the cover 110. In these embodiments, by providing the crossbeam and partition, the current-carrying assembly 500 can be mounted on the partition 190, resulting in a neater and more organized installation. The crossbeam 180 can reinforce the housing 100 and support the partition 190 and the flow assembly 500, making the structure of the housing 100 more stable.

[0049] In some embodiments, referring to Figure 5, the crossbeam 180 may include a first portion 181, a second portion 182, and a third portion 183. Along the third direction, the first portion 181 may include a parallel first side 184 and a second side 185. The second portion 182 is bent and connected to the first side 184, and the third portion 183 is bent and connected to the second side 185. During installation, the third portion 183 can be connected to the BMS component 300 via screws, riveting, or other means. The second portion 182 can also be connected to the BMS component 300 via screws, riveting, or other means. This allows the BMS component 300 to be stably fixed to the crossbeam 180. The first portion 181 and the second portion 182 are spaced apart along the first direction, and the first portion 181 and the third portion 183 are also spaced apart along the first direction. This creates a gap between the first portion and the BMS component 300 in the first direction, which can serve as a reserved installation space.

[0050] In some embodiments, referring to FIG4, the BMS component 300 can also be connected to the bottom wall 130, thereby fixing the BMS component 300 to the first mounting cavity 120 along the first direction.

[0051] Referring to Figures 7 and 8, in some embodiments, the BMS component 300 may include a BMS and a BMS support 303, wherein there may be one or more BMS, for example, there may be three BMS.

[0052] In some embodiments, the BMS bracket 303 is connected to the bottom wall 130 via a fastener 305. The connection between the BMS bracket 303 and the bottom wall 130 can be by screwing, riveting, welding, etc. In some embodiments, the fastener 305 can be a bolt.

[0053] Referring to Figures 5, 6, 7, and 8, in some embodiments, the BMS component 300 is mounted on the side of the partition 190 facing away from the cover 110. The BMS component 300 can be detachably connected to the partition 190, for example, by screws or snap-fits. This allows for a smaller gap between the BMS component 300 and the partition 190, resulting in a more compact overall structure of the high-voltage power distribution unit.

[0054] Referring to Figures 5, 6, 7, and 8, in some embodiments, the BMS component 300 can be installed on the side of the crossbeam 180 facing away from the cover 110, and the BMS component 300 is fixedly connected to the crossbeam 180. The crossbeam 180 has high strength and can bear the weight of the BMS component 300 without easily being damaged. Referring to Figures 5, 6, 7, and 8, in some embodiments, a mounting bracket can be connected to the side of the BMS component 300, which can be used to connect to the side of the crossbeam 180 facing away from the cover 110.

[0055] Referring to Figures 3 and 4, in some embodiments, the housing 100 further includes a third sidewall 101 and a fourth sidewall 103 arranged along a third direction, perpendicular to the first direction and perpendicular to the second direction. The partition 190 extends along the third direction. The current-carrying assembly 500 includes multiple relays 501 and a TBOX signal box 503 electrically connected to the BMS assembly 300. The multiple relays 501 are spaced apart along the third direction on the partition 190, and are arranged along the extension direction of the partition 190, thus providing a large heat dissipation space between the multiple relays 501 and achieving good heat dissipation. The TBOX signal box 503 is disposed on the fourth sidewall 103 and spaced apart from the relays 501. In these embodiments, the multiple relays 501 are spaced apart along the third direction on the partition 190, and the TBOX signal box 503 is disposed on the fourth sidewall 103, which can fully utilize the space within the second mounting cavity 140, resulting in a compact structure.

[0056] The Telematics Box (TBOX) collects data from various electronic control units (ECUs) in the vehicle, such as engine operating status, vehicle speed, and fault codes. After integrating and packaging this data, the TBOX can transmit it via a network (such as 4G / 5G) to the vehicle manufacturer's backend server or other relevant remote service platforms. Simultaneously, it also receives commands from remote locations, such as remotely starting the vehicle or unlocking the doors, and forwards these commands to the corresponding ECUs within the vehicle for execution.

[0057] Referring to Figure 4, in some embodiments, the TBOX signal box 503 can be located at least partially above the relay 501. Here, "above" refers to the side of the relay 501 near the cover 110. There is a certain space between the top of the relay 501 and the cover 110. By placing the TBOX signal box 503 on the fourth side wall 103 and placing the TBOX signal box 503 in the space between the top of the relay 501 and the cover 110, the space within the second mounting cavity 140 can be utilized more fully.

[0058] Referring to Figures 2 and 4, in some embodiments, the high-voltage power distribution unit further includes a second connector 400 and an insulating post 600. The high-voltage power distribution unit is connected to the battery pack via the second connector 400. The second connector 400 is mounted on the second sidewall 170, and at least a portion of the second connector 400 is located on the outside of the housing 100 to facilitate connection with the battery pack.

[0059] The overcurrent assembly 500 also includes a conductive bus 504, which may include a copper conductive bus, an aluminum conductive bus, etc. The relays of the overcurrent assembly 500 are connected to the first connector 200 through the conductive bus 504.

[0060] One end of the conductive bus 504 is connected to the side of the relay 501 away from the partition 190, thus creating a large gap between the conductive bus 504 and the partition 190 for heat dissipation, while maintaining a compact structure. At least a portion of the conductive bus 504 and the partition 190 form a first chamber 104. The other end of the conductive bus 504 is connected to the second connector 400. An insulating post 600 is installed in the first chamber 104, with its opposite ends connected to the partition 190 and the conductive bus 504, respectively. In these embodiments, the insulating post 600 supports the conductive bus 504, making it less likely for the conductive bus 504 to exert excessive pressure on the relay 501, while maintaining a large heat dissipation gap (such as the first chamber 104), which is beneficial for the heat dissipation of the overcurrent assembly 500. The insulating post 600 provides electrical insulation, preventing unwanted current conduction between different circuits and preventing short circuits.

[0061] In some embodiments, the insulating post 600 has a first mating portion at one end near the partition 190, and the high-voltage distribution unit further includes a mounting base 810 that mates with the first mating portion. The mounting base 810 is fixed to the side of the partition 190 facing the box cover. In these embodiments, the partition may have a mounting base 810 connected to the insulating post 600, which facilitates positioning of the insulating post 600 and allows operators to easily install the insulating post 600 to the relevant position on the partition 190.

[0062] Referring to Figure 2, the mounting base 810 includes a support portion 811 and a second mating portion 813. The support portion 811 is provided with a second chamber 812. The second mating portion 813 is installed on the side of the support portion 811 away from the partition 190. The second mating portion 813 is connected to the first mating portion 603 to connect the insulating column 600 and the partition 190. The second chamber 812 is located between the second mating portion 813 and the partition 190.

[0063] The insulating column 600 is better mounted on the partition 190 by engaging with the second mating portion of the mounting base 810 on the partition 190 and the first mating portion 603 of the insulating column 600. In some embodiments, the first mating portion of the insulating column 600 can be a recess, and the second mating portion 813 of the mounting base 810 can be a protrusion, with the protrusion engaging with the recess to connect the insulating column 600 to the mounting base 810. In other embodiments, the first mating portion of the insulating column 600 can be a protrusion, and the second mating portion 813 of the mounting base 810 can be a recess, with the protrusion engaging with the recess to connect the insulating column 600 to the mounting base 810. Furthermore, in these embodiments, the provision of a second chamber 812 between the second mating portion and the partition 190 facilitates better heat dissipation.

[0064] Referring to Figure 4, in some embodiments, the end of the insulating post 600 near the cover may have a slot 601, the conductive bus 504 has a through hole, and the high-voltage distribution unit also includes a locking fastener 820, which passes through the through hole 505 and the slot 601 in sequence to fasten the insulating post 600 and the conductive bus 504. The slot 601 at the end of the insulating post 600 near the cover facilitates the connection between the insulating post 600 and the conductive bus 504.

[0065] In some embodiments, the high-voltage power distribution unit may further include a Hall sensor 900, which is electrically connected to a relay 501 and a battery pack, and is disposed between the second connector 400 and the relay 501.

[0066] Hall effect sensors detect current using the principle of magnetic field induction, eliminating the need for direct electrical connection to the circuit being measured. In a vehicle's high-voltage power distribution unit, they can be conveniently installed around the busbars. When current flows through the busbars, a magnetic field is generated around them; the Hall effect sensor detects changes in the strength of this magnetic field, thus determining the current magnitude. This non-invasive measurement method is less likely to interfere with normal circuit operation or cause additional impact on the internal electrical structure of the PDU. The Hall effect sensor 900 also provides crucial current information to the BMS (Battery Management System). The BMS can use this information to control the charging and discharging process of the battery pack, such as preventing overcharging or over-discharging, ensuring the battery pack operates safely and efficiently, and extending its lifespan.

[0067] The high-voltage power distribution unit provided in this application embodiment has the overcurrent component 500 and the BMS component 300 arranged in layers along the first direction on the housing 100, which effectively utilizes the space in the length, width and height directions of the high-voltage power distribution unit, making the overall structure of the high-voltage power distribution unit more compact.

[0068] Secondly, embodiments of this application also provide a vehicle that includes the aforementioned high-voltage power distribution unit.

[0069] In this embodiment, the internal space of the housing 100 is divided into two chambers arranged along a first direction: a first mounting chamber 120 and a second mounting chamber 140. The BMS assembly 300 and the overcurrent assembly 500 are disposed in the second mounting chamber 140 and the first mounting chamber 120, respectively, which fully utilizes the space in the height direction of the high-voltage power distribution unit, resulting in shorter wiring distances and a more compact high-voltage power distribution unit. Furthermore, in this embodiment, one end of the wiring harness assembly 700 is connected to the overcurrent assembly 500, and the other end of the wiring harness assembly 700 passes through the wiring space 150 located on one side of the BMS assembly 300 and connects to the BMS assembly 300. Within the first mounting chamber 120, the wiring of the wiring harness assembly is relatively concentrated, resulting in a neat and compact structure, occupying less space, and facilitating operation and organization by the operator.

[0070] In this embodiment, the internal structure of the high-voltage power distribution unit is compact, allowing it to have a small volume. The length, width, and height of the high-voltage power distribution unit can correspond to the length, width, and height of the vehicle, minimizing its footprint in these dimensions while maximizing the use of space in the vehicle's height direction.

[0071] In some embodiments, the high-voltage power distribution unit in this application can serve as a secondary high-voltage power distribution unit for the vehicle, and the vehicle may also include a primary high-voltage power distribution unit. The vehicle can then perform battery swapping.

[0072] The high-voltage power distribution unit (slave high-voltage power distribution unit) in this embodiment can cooperate with the main high-voltage power distribution unit. The slave high-voltage power distribution unit is directly connected to the battery pack and can be located inside or outside the battery pack. It records and manages the current, voltage, and other parameters of the battery pack. During battery swapping, the high-voltage power distribution unit (slave high-voltage power distribution unit) and the battery pack can be replaced simultaneously. In some embodiments, the vehicle can perform bottom battery swapping.

[0073] In some embodiments, the correctness of the battery's connection to the vehicle's electrical system is detected during the battery swapping process by cooperating with the main high-voltage power distribution unit. If there are issues such as loose connections or poor contact, abnormal circuit parameters may be detected by the high-voltage power distribution unit or the main high-voltage power distribution unit, and a warning may be issued to the user or maintenance personnel through the vehicle's warning system.

[0074] In some embodiments, the high-voltage power distribution unit (from the high-voltage power distribution unit) in this application embodiment can be a high-voltage power distribution unit with three-branch power swapping, and the first connector 200 can be a power swapping connector.

Claims

1. A high-voltage power distribution unit, the high-voltage power distribution unit comprising: The housing (100) includes a cover (110) and a bottom wall (130) arranged along a first direction, wherein a first mounting cavity (120) and a second mounting cavity (140) are formed between the cover (110) and the bottom wall (130), and the first mounting cavity (120) and the second mounting cavity (140) are arranged along the first direction; BMS component (300) is installed in the first mounting cavity (120). Along the second direction, a wiring space (150) is formed between one side of the BMS component (300) and the housing (100). The second direction is perpendicular to the first direction. The BMS component (300) is electrically connected to the battery pack and external electrical equipment respectively. A current-carrying assembly (500) is installed in the second mounting cavity (140). The current-carrying assembly (500) includes a battery-side module (510) and a load-side module (530) electrically connected to each other. The battery-side module (510) is configured to be electrically connected to a battery pack, and the load-side module (530) is configured to be electrically connected to an external electrical device. A wiring harness assembly (700) is configured to pass through the wiring space (150) to connect the BMS assembly (300) and the overcurrent assembly (500).

2. The high-voltage power distribution unit according to claim 1, wherein, The second mounting cavity (140) is located near the cover (110). The high-voltage power distribution unit also includes a first connector (200) mounted on the cover (110). The first connector (200) includes a first connection end (210) and a second connection end (230). The first connection end (210) is located in the second mounting cavity (140) and is electrically connected to the overcurrent assembly (500). The second connection end (230) is located on the side of the cover (110) away from the bottom wall (130) and is configured to connect to external electrical equipment.

3. The high-voltage power distribution unit according to claim 1, wherein the housing (100) further comprises a first sidewall (160) and a second sidewall (170) disposed along the second direction. The housing (100) further includes a crossbeam (180) and a partition (190) disposed between the cover (110) and the bottom wall (130). The two opposite ends of the crossbeam (180) are fixed to the first side wall (160) and the second side wall (170), respectively. The partition (190) is fixed to the side of the crossbeam (180) near the cover (110). The partition (190) and the cover (110) form the second mounting cavity (140). The flow-through assembly (500) is installed on the side of the partition (190) facing the cover (110).

4. The high-voltage power distribution unit according to claim 3, wherein the housing (100) further comprises a third sidewall (101) and a fourth sidewall (103) disposed along a third direction, the third direction being perpendicular to the first direction and the third direction being perpendicular to the second direction, the partition (190) extending along the third direction, the overcurrent assembly (500) comprising a plurality of relays (501) and a TBOX signal box (503) electrically connected to the BMS assembly (300), the plurality of relays (501) being spaced apart along the third direction on the partition (190), the TBOX signal box (503) being disposed on the fourth sidewall (103) and spaced apart from the relays (501).

5. The high-voltage power distribution unit according to claim 4, wherein the high-voltage power distribution unit further comprises a second connector (400) and an insulating post (600). The second connector (400) is mounted on the second sidewall (170), and at least a portion of the second connector (400) is located outside the housing (100) and configured to connect to the battery pack; The overcurrent assembly (500) further includes a conductive bus (504), one end of which is connected to the side of the relay (501) away from the partition (190). At least a portion of the conductive bus (504) and the partition (190) form a first chamber (104). The other end of the conductive bus (504) is connected to the second connector (400). An insulating post (600) is installed in the first chamber (104), and the opposite ends of the insulating post (600) are respectively connected to the partition (190) and the conductive bus (504).

6. The high-voltage power distribution unit according to claim 5, wherein, The insulating column (600) has a first mating part (603) at one end near the partition (190); the high-voltage power distribution unit also includes a mounting base (810) that is connected to the first mating part, and the mounting base (810) is fixed to the side of the partition (190) facing the box cover (110).

7. The high-voltage power distribution unit according to claim 6, wherein, The mounting base (810) includes a support portion (811) and a second mating portion (813). The support portion (811) is provided with a second chamber (812). The second mating portion (813) is installed on the side of the support portion (811) away from the partition plate (190). The second mating portion (813) is connected to the first mating portion (603) to connect the insulating column (600) and the partition plate (190). The second chamber (812) is located between the second mating portion (813) and the partition plate (190).

8. The high-voltage power distribution unit according to claim 5, wherein, The insulating post (600) has a slot (601) at one end near the box cover (110), the conductive bus (504) has a through hole (505), and the high-voltage power distribution unit also includes a locking fastener (820). The locking fastener (820) is sequentially inserted into the through hole (505) and the slot (601) to fasten the insulating post (600) and the conductive bus (504).

9. The high-voltage power distribution unit according to any one of claims 4 to 8, wherein the high-voltage power distribution unit further comprises a Hall sensor (900), the Hall sensor (900) being electrically connected to the relay (501), the Hall sensor (900) being configured to be electrically connected to the battery pack, and the Hall sensor (900) being disposed between the second connector (400) and the relay (501).

10. A vehicle comprising a high-voltage power distribution unit as claimed in any one of claims 1 to 9.

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