Vehicle-mounted five-in-one integrated controller of new energy automobile
阅读说明：本技术 一种新能源汽车的车载五合一集成控制器 (Vehicle-mounted five-in-one integrated controller of new energy automobile ) 是由 黄磊磊 郝义国 邵毅 于 2019-08-19 设计创作，主要内容包括：一种新能源汽车的车载五合一集成控制器,集成了车载充电机OBC模块、高压配电PDU模块、DC/DC降压模块、绝缘监测模块、接触器烧结检测模块五个功能模块于一体,五合一集成控制器内部结构为低压控制层、高压功率层、水冷散热层,5个控制器集成在一个金属壳体类,减少高低压线束的长度,能够提高整车抗电磁干扰能力；减轻了整车质量,降低整车能耗,提高车辆续航里程；控制器的集成有利于提高控制器功能的稳定性,便于后期的程序更新及维护。(A vehicle-mounted five-in-one integrated controller of a new energy automobile integrates five functional modules, namely a vehicle-mounted charger OBC module, a high-voltage distribution PDU (power distribution unit) module, a DC/DC voltage reduction module, an insulation monitoring module and a contactor sintering detection module, and the internal structure of the five-in-one integrated controller is a low-voltage control layer, a high-voltage power layer and a water-cooling heat dissipation layer, 5 controllers are integrated in a metal shell, so that the length of a high-voltage wire harness and a low-voltage wire harness is reduced, and the electromagnetic interference resistance of the whole automobile can be improved; the whole vehicle mass is reduced, the whole vehicle energy consumption is reduced, and the vehicle endurance mileage is improved; the integration of the controller is beneficial to improving the stability of the functions of the controller, and is convenient for later program updating and maintenance.)
1. A vehicle-mounted five-in-one integrated controller of a new energy automobile is characterized in that five functional modules, namely a vehicle-mounted charger OBC module, a high-voltage distribution PDU (power distribution unit) module, a DC/DC voltage reduction module, an insulation monitoring module and a contactor sintering detection module, are integrated into a whole, the OBC module, the DC/DC voltage reduction module, the insulation monitoring module and the contactor sintering detection module are directly connected with the PDU module, the DC/DC voltage reduction module is also connected with a low-voltage 12V storage battery, the OBC module is connected with an alternating current charging port of the whole automobile, and the PDU is connected with a direct current bus of the whole automobile; when the whole vehicle is charged by alternating current, the OBC module converts 220V of an alternating current power grid into high-voltage direct current of the whole vehicle, and a power battery of the whole vehicle is charged through the PDU module; when the whole vehicle power battery can provide a power source for a whole vehicle, the whole vehicle power battery inputs the whole vehicle high-voltage power to the DC/DC voltage reduction module through the PDU module, and the DC/DC voltage reduction module converts the whole vehicle high-voltage power into low-voltage direct current to charge the low-voltage 12V storage battery; when the power battery of the whole vehicle cannot provide a power source for the whole vehicle, the OBC module converts the 220V alternating current into high-voltage direct current, and the high-voltage direct current is converted into low-voltage direct current through the PDU module and the DC/DC voltage reduction module to charge a low-voltage 12V storage battery; the insulation monitoring module detects the insulation resistance value of the five-in-one integrated controller, stops the work of the five-in-one integrated controller when the insulation resistance value is smaller than the voltage value of the whole vehicle high-voltage direct current (HVDC) 100 omega/V, and sends an insulation alarm message to a whole vehicle network through a CAN bus; the PDU module comprises a contactor, before the contactor in the PDU module is disconnected, the contactor sintering detection module carries out sintering detection on the contactor, the low-voltage control layer sends the sintering state of the contactor to the bus in the form of a CAN message, and the controller on the bus collects and analyzes the CAN message.
2. The vehicle-mounted five-in-one integrated controller of the new energy automobile according to claim 1, characterized in that: the top layer of the internal structure of the five-in-one integrated controller is a low-voltage control layer, the middle layer of the internal structure of the five-in-one integrated controller is a high-voltage power layer, and the bottom layer of the internal structure of the five-in-one integrated controller is a water-cooling heat dissipation layer.
3. The vehicle-mounted five-in-one integrated controller of the new energy automobile according to claim 2, characterized in that: the low-voltage control layer is a PCB and is responsible for a low-voltage electric appliance of the five-in-one integrated controller, low-voltage communication and control of the high-voltage power board.
4. The vehicle-mounted five-in-one integrated controller of the new energy automobile according to claim 2, characterized in that: the high-voltage power layer comprises an IGBT module, a high-voltage fuse and a high-voltage contactor and is responsible for high-voltage power distribution, rectification and DC/DC voltage reduction of the whole vehicle.
5. The vehicle-mounted five-in-one integrated controller of the new energy automobile according to claim 2, characterized in that: the water-cooling heat dissipation layer is a laying layer of a water-cooling pipeline of the five-in-one integrated controller and provides heat dissipation for the five-in-one integrated controller.
Technical Field
The invention relates to the field of automobile controllers, in particular to a vehicle-mounted five-in-one integrated controller of a new energy automobile.
Background
With the gradual popularization of new energy vehicles and the market demands, new energy manufacturers have made great progress in the aspect of vehicle intellectualization, which also leads to the continuous increase of the functions of the whole vehicle, various controllers on the whole vehicle are also continuously increased, high-voltage wire harnesses and low-voltage wire harnesses of the whole vehicle are continuously increased, the quality of the whole vehicle is also continuously increased, and the serious challenge is brought to the light weight of the whole vehicle; a large amount of controllers also make the electromagnetic compatibility and the reliability of whole car receive the influence, and the integration of controller plays the salient role in the aspects of reducing whole car quality, improving the electromagnetic compatibility and the reliability of whole car, reducing whole car energy consumption, etc.
Disclosure of Invention
In view of this, the invention provides a vehicle-mounted five-in-one integrated controller of a new energy automobile.
1. A vehicle-mounted five-in-one integrated controller of a new energy automobile is characterized in that five functional modules, namely a vehicle-mounted charger OBC module, a high-voltage distribution PDU (power distribution unit) module, a DC/DC voltage reduction module, an insulation monitoring module and a contactor sintering detection module, are integrated into a whole, the OBC module, the DC/DC voltage reduction module, the insulation monitoring module and the contactor sintering detection module are directly connected with the PDU module, the DC/DC voltage reduction module is also connected with a low-
Furthermore, the top layer of the internal structure of the five-in-one integrated controller is a low-voltage control layer, the middle layer of the internal structure of the five-in-one integrated controller is a high-voltage power layer, and the bottom layer of the internal structure of the five-in-one integrated controller is a water-cooling heat dissipation layer.
Furthermore, the low-voltage control layer is a PCB and is responsible for a low-voltage electrical appliance of the five-in-one integrated controller, low-voltage communication and control of the high-voltage power board.
Furthermore, the high-voltage power layer comprises an IGBT module, a high-voltage fuse and a high-voltage contactor and is responsible for high-voltage power distribution, rectification and DC/DC voltage reduction of the whole vehicle.
Furthermore, the water-cooling heat dissipation layer is a laying layer of a water-cooling pipeline of the five-in-one integrated controller and provides heat dissipation for the five-in-one integrated controller.
The technical scheme provided by the invention has the beneficial effects that: (1) the controller integrates and reduces the length of the high-voltage and low-voltage wire harnesses, and the electromagnetic interference resistance of the whole vehicle can be improved; (2) the system can reduce the whole vehicle mass, reduce the whole vehicle energy consumption, improve the vehicle endurance mileage, and is favorable for improving the stability of the controller function, and facilitating the later program updating and maintenance.
Drawings
The invention will be further described with reference to the accompanying drawings and examples, in which:
FIG. 1 is a functional partition diagram of a vehicle-mounted five-in-one integrated controller of a new energy automobile;
fig. 2 is an internal structure diagram of a vehicle-mounted five-in-one integrated controller of the new energy automobile.
Detailed Description
For a more clear understanding of the technical features, objects and effects of the present invention, embodiments of the present invention will now be described in detail with reference to the accompanying drawings.
1. A vehicle-mounted five-in-one integrated controller of a new energy automobile integrates an OBC module, a high-voltage power distribution PDU module, a DC/DC voltage reduction module, an insulation monitoring module and a contactor sintering detection module;
as shown in fig. 1, the OBC module, the DC/DC voltage reduction module, the insulation monitoring module and the contactor sintering detection module are directly connected to the PDU module, the PDU module is connected to the DC bus of the entire vehicle, the DC/DC voltage reduction module is connected to the low-
(1) during the alternating current charging of the whole vehicle, the five-in-one integrated controller and the alternating current charging cabinet carry out hard line and CAN message interaction, the alternating current charging of the whole vehicle is carried out after the interaction is successful, in the alternating current charging process, an OBC module of the five-in-one integrated controller converts 220V of an alternating current power grid into high voltage direct current of the whole vehicle, and a PDU module connects the high voltage direct current converted by the OBC module to two ends of a power battery through an internal high voltage distribution circuit to charge the power battery of the whole vehicle;
(2) under the condition that the Ready is electrified on the high voltage of the whole vehicle, the whole vehicle power battery inputs the high voltage of the whole vehicle to the high voltage input end of the DC/DC voltage reduction module through the PDU module, and the DC/DC voltage reduction module converts the high voltage direct current into low voltage direct current to charge the
(3) when a power battery of the whole vehicle has serious faults and cannot provide a power source for the whole vehicle, a low-
(4) the insulation monitoring module detects the insulation resistance value of the whole five-in-one integrated controller, stops the work of the five-in-one integrated controller when the insulation resistance value is smaller than the voltage value of the whole vehicle high-voltage direct current (HVDC) 100 omega/V, and sends an insulation alarm message to a whole vehicle network through a CAN bus;
(5) when the whole vehicle needs to be electrified under high voltage, the contactor in the PDU module needs to execute disconnection action, the contactor sintering detection module needs to carry out sintering detection on the contactor and sends the state of whether the contactor is sintered to the bus in the form of CAN messages, and when the contactor is sintered, a driver needs to maintain the vehicle, replace the sintered contactor and prevent dangerous accidents.
As shown in fig. 2, the top layer of the internal structure of the five-in-one integrated controller is a low-voltage control layer, the middle layer is a high-voltage power layer, and the bottom layer is a water-cooling heat dissipation layer, wherein the OBC module, the PDU module and the DC/DC voltage reduction module belong to the high-voltage power layer, and the insulation monitoring module and the contactor sintering detection module belong to the low-voltage control layer.
The low-voltage control layer is a PCB and is responsible for a low-voltage electric appliance of the five-in-one integrated controller, low-voltage communication and control of the high-voltage power board.
The high-voltage power layer comprises an IGBT module, a high-voltage fuse and a high-voltage contactor and is responsible for high-voltage power distribution, rectification and DC/DC voltage reduction of the whole vehicle.
The water-cooling heat dissipation layer is a laying layer of a water-cooling pipeline of the five-in-one integrated controller and provides heat dissipation for the five-in-one integrated controller.
The OBC module, the PDU module, the DC/DC voltage reduction module, the insulation monitoring module and the contactor sintering detection module are integrated in the aluminum alloy cuboid shell, so that the electromagnetic compatibility of the device can be improved, the quality of the whole vehicle is reduced, the whole vehicle arrangement is facilitated, and the integrated arrangement of a cooling system is facilitated.
The five-in-one integrated controller integrates the high-voltage connection, the low-voltage connection, the CAN communication and the like of the controller, and is favorable for improving the electrical reliability of products and the reliability of network communication, so that the whole vehicle is safer and more reliable.
While the present invention has been described with reference to the embodiments shown in the drawings, the present invention is not limited to the embodiments, which are illustrative and not restrictive, and it will be apparent to those skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope of the invention as defined in the appended claims.
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