CN111629537A

CN111629537A - Method for producing a switch box, in particular a high-voltage switch box, for an electrically driven vehicle, and switch box

Info

Publication number: CN111629537A
Application number: CN202010080312.3A
Authority: CN
Inventors: 莱因霍尔德·哈默勒
Original assignee: Lisa Draexlmaier GmbH
Current assignee: Lisa Draexlmaier GmbH
Priority date: 2019-02-27
Filing date: 2020-02-05
Publication date: 2020-09-04
Anticipated expiration: 2040-02-05
Also published as: CN111629537B; DE102019104962A1; DE102019104962B4

Abstract

The invention relates to a method for producing a switch box, in particular a high-voltage switch box (10), for an electrically driven motor vehicle, comprising the following steps: matching the individual components (28, 42, 44, 50, 52, 58, 68) of the switch box to corresponding pre-installed components (12, 14, 16, 18, 20, 22, 26); pre-mounting the components (28, 42, 44, 50, 52, 58, 68) to respective pre-mounted assemblies (12, 14, 16, 18, 20, 22, 26) according to the matching; the switch box is mounted by assembling the pre-mounted components (12, 14, 16, 18, 20, 22, 26) together in layers one after the other in a single mounting direction (30). The invention further relates to a switch box, in particular a high-voltage switch box (10), for an electrically driven motor vehicle.

Description

Method for producing a switch box, in particular a high-voltage switch box, for an electrically driven vehicle, and switch box

Technical Field

The invention relates to a method for producing a switch box, in particular a high-voltage switch box, for an electrically driven vehicle and to a switch box.

Background

High-voltage systems or high voltages (HV for short) are an independent concept in vehicle technology for systems which are operated with an ac voltage of 30V to 1kV or with a dc voltage of 60V to 1.5 kV. The concept of high voltage should not be confused with the concept of high voltage in power technology. In the field of vehicles, systems which are operated with an ac voltage of up to and including 30V or with a dc voltage of up to and including 60V are referred to as low-voltage systems or low voltages (NV for short) and are used primarily in the vehicle electrical system of the vehicle. This distinction is important in particular for vehicles with electric drive (e.g. hybrid vehicles, vehicles with fuel cells or batteries). The high-voltage switch box is therefore designed for a correspondingly high voltage.

In purely electric or hybrid vehicles, a so-called high-voltage switch box is used as an interface between the battery unit and the high-voltage on-board electrical system. In other words, the high-voltage switch box thus serves as an interface between the battery unit of the storage system and the high-voltage on-board electrical system of the vehicle. High-voltage switch boxes usually comprise separating elements, fuses, high-precision measurement technology components and safety-relevant and relatively complex control electronics.

The central element of such high-voltage switch boxes is usually a battery control device which detects all relevant data of the battery system, for example all relevant data of current and/or voltage sensors or battery cell controllers. One or more current-voltage sensors typically determine accurate data for battery management and provide a very accurate determination of the state of charge of the high voltage battery and the range of the vehicle involved. In addition to the current-voltage sensor, the high-voltage switch box usually also contains a control device for the electrical heating of the high-voltage accumulator concerned, as well as other electrical components responsible for opening and closing the high-voltage current path, the controlled starting of the vehicle concerned, and the safety in the event of a fault.

Due to the increasing degree of electrification of automobiles, the complexity of components in electrically driven vehicles and hybrid vehicles is increasing. This leaves the automotive field open to a process of continuous learning and optimization, as the required experience must first be collected. When analyzing a switch box or a high-voltage switch box, the switch box must obviously assume additional functions when used in an electric vehicle. In this case, the safety of the persons to be transported and the monitoring of the battery must also be taken into account, in contrast to the case of internal combustion engines.

In general, the production of such a switch box, and in particular the installation of such a switch box, is still largely done manually, in particular due to its complexity and its development in the customization of the vehicle. The reason for this may be, for example, a non-ideal installation space requirement, which in turn may lead to disadvantageous boundary conditions in terms of installation technology for the design of the current rail of the switch box. Furthermore, when mounting such switch boxes, it is often required to specify a plurality of mounting and screwing directions, and a relatively small-scale cable set is required for the wiring for the sensor device, the actuator device and further components.

The respective components of the switch box to be produced are therefore usually arranged in a vehicle-customized manner and connected to correspondingly designed current rails. The vehicle-customized arrangement of the components often results in a large number of mounting and screwing directions, so that automatic mounting is difficult or even impossible. The same applies to the installation of cable groups on switch boxes of this type, the small scale complexity of which cannot be economically automated and which moreover also place extremely high demands on the manual installation in terms of error rates. Furthermore, the design of such closures in terms of vehicle customization requires new tests in terms of functional load-bearing capacity, crash stability and electromagnetic compatibility for each structural form, so that such tests can lead to extremely high costs.

Disclosure of Invention

The object of the present invention is therefore to provide a solution by means of which a particularly simple production of a switch box, in particular a high-voltage switch box, for an electrically driven vehicle is achieved.

This object is achieved by a method for producing a switch box, in particular a high-voltage switch box, for an electrically driven vehicle and by a switch box having the features of the independent claims. Other possible configurations of the invention are given in the dependent claims.

In the method according to the invention for producing a switch box, in particular a high-voltage switch box, for an electrically driven vehicle, the individual components of the switch box are assigned to the respective pre-installed components. Upon the mating, the component is pre-mounted to the corresponding pre-mounted assembly. The switch box is then mounted by assembling the pre-mounted components together in layers one after the other in a unique mounting direction.

In this case, the pre-assembled assembly is assembled separately from the component carrier, which is for example a printed circuit board. For example, the pre-assembled assembly may include control electronics, component mounts, low voltage contacts, one or more current rail composites, or a cooling plate.

The arrangement of the individual components (i.e. the individual components of the preassembled assembly) can follow a predefined scheme, which enables the individual preassembled assemblies to be assembled one after the other into a high-voltage switchgear cabinet or used in a high-voltage switchgear cabinet. In other words, the components as well as the pre-mounted assemblies may be selected such that assembly of the various pre-mounted assemblies in a unique mounting direction is enabled.

The pre-installation assembly can thus be constructed in a modular and layered manner in one installation direction. The layout of the high-voltage switch box can have a standardized layout in terms of its component parts (i.e. in terms of individual components) independently of the specific construction of the high-voltage switch box, which layout is designed for optimized production. With this layout the preassembled assembly can be determined.

Assembly means in particular that the individual pre-mounted components are connected to one another, for example in a form-fitting and/or force-fitting manner. In particular, it is provided that a standardized layout of the switch box is provided when the switch box is produced, which enables production at a low unit price or production of a large number of parts. Furthermore, with a standardized layout of the switch boxes, no costly comprehensive testing for ensuring mass production is required for each new construction model. Furthermore, standardized switch boxes can be introduced as an integrated part of the module, i.e. the high-voltage battery.

The invention can therefore also comprise a method for producing different variants of a switch box, wherein in this case a standardized layout or a standardized basic configuration is set for all variants of the switch box, in particular in the form of variants. Different pre-mounted components can be set in a standardized manner, for example, depending on the functional aspects of the switch box. Thus, within a single pre-mounted assembly, the specific composition of the pre-mounted assembly consisting of the individual components may be varied correspondingly, depending on the variant. In all variants of the switch box, the only installation direction remains unchanged, so that in all variants of the switch box to be produced, the preassembled components can be assembled together in layers one behind the other in one direction.

For example, a scalable switch cabinet can also be produced by the method, wherein the proportions and dimensions of the individual components and/or the number of corresponding components can be relevant. In the method according to the invention, a particularly strict focus is placed on the optimized production of the switch box or of different switch box variants. The effort for manufacturing the switch box or different switch box variants can thus be significantly reduced.

In the method according to the invention, it is important to divide the component or the individual component into said pre-mounted assemblies which are pre-mounted individually. Due to the modular and layered structure of the pre-installation assembly for the switch box in a single installation direction, standardized production of the switch box or different switch box variants is possible. The individual pre-assembled components are connected to each other by suitable joining methods, for example by screwing, welding, hot stamping, soldering, laser bonding, form fitting, etc., to name only a few possible connection methods.

In addition, compensation for existing or occurring manufacturing and installation tolerances is ensured when the pre-mounted assembly is mounted as a switch box. The design of the assembly of pre-mounted components and the entire switch box takes into account in particular the requirements of automated manufacture and the requirements of electromagnetic compatibility.

Thus, by means of the method according to the invention, a single switch box variant or different switch box variants can be produced in a particularly simple, standardized and therefore inexpensive manner. The production of the pre-installation assembly and the assembly of the finished switch box are optimized in particular with regard to the machine manufacturability, and therefore the production of the switch box, in particular the installation of the switch box, is achieved in a standardized production sequence (in particular in the form of an automated installation line). Provision can therefore be made for the assembly of the preassembled components to be carried out automatically. The method according to the invention thus makes it possible to produce a switch box which is constructed in a modular manner and is scalable in terms of its performance range in a particularly simple and cost-effective manner. The installation or manufacture of the individual pre-installed components can also be effected automatically, which means that manual work steps and thus the associated effort and costs can be saved.

One possible embodiment of the invention provides that at least one of the premounted components comprises a current rail composite, which is premounted from individual current rail sections in an electrically conductive manner and is equipped (in particular, equipped in an automated manner) with at least one component. In other words, the current rail composite is a form of a current rail set. In this case, it can be provided that a respective current rail composite made of individual current rail sections is provided separately for the positive pole and the ground composite. The equipping with components or parts in the form of, for example, high-voltage contactors, safeties, pyrotechnic elements, etc. can be carried out in an automated manner. In this way, the current rail composite concerned, and the corresponding components or parts of the current rail composite, can be equipped in a particularly simple, standardized and cost-effective manner.

Another possible embodiment of the invention provides that the current rail sections are positioned relative to one another in a defined arrangement and are coated, in particular injection-molded, with a thermally conductive and electrically insulating plastic and then connected to one another in an electrically conductive manner. In this way, the individual current rails can already be fixed to one another in their intended arrangement by means of plastic. Furthermore, the plastic can be coated or injection-molded in such a way that, for example, receiving regions for different components or parts are provided, which can then still be connected to the current rail section in an electrically conductive manner. By positioning the current rail sections in their intended arrangement relative to one another and then coating, in particular injection molding, with the plastic, the current rail sections can be fixed in their intended arrangement in a particularly simple and automatable manner. This then simplifies the electrically conductive connection of the individual current rail sections, which in turn can be automated.

Another possible embodiment of the invention provides that, after the sheathing with plastic, the plastic is removed at predetermined locations and the current rail sections are brought into contact with one another there and/or at least one component is brought into contact at one of the current rail sections. In other words, it is possible, for example, to provide some free cuts in the plastic to provide access to the welding region or other fastening means, so that the current rail sections can be contacted with one another in a particularly simple manner and/or so that components or parts can be contacted at the current rail sections in a particularly simple and reliable manner.

According to a further possible embodiment of the invention, it is provided that the at least one premounted component is a cooling plate through which a cooling medium can flow, which is premounted and coated (in particular injection-coated) with a thermally conductive and electrically insulating plastic. The cooling plate may be made of, for example, aluminum. Furthermore, the cooling plate can be produced, for example, by roll bonding or a hollow chamber method, wherein the cooling plate can be provided with a flow-optimized channel geometry. By coating, in particular injection-molding, the cooling plate with a thermally conductive and insulating plastic, it is possible on the one hand to ensure that good heat dissipation is possible via the cooling plate, while on the other hand it is possible to ensure that no short circuits occur between the flow-conducting parts.

Another possible embodiment of the invention provides that at least some of the components are connected to one another in an electrically conductive manner by at least one electrically conductive connecting device, which comprises a leadframe (Stanzgitter) with a plurality of electrical conductors. A plurality of lead frames may also be provided, for example to connect the high-voltage components and the low-voltage components to one another in an electrically conductive manner. These lead frames, which serve as electrically conductive connecting means and are provided with a plurality of electrical conductors, can largely or completely replace the classic cable set in the case of a switch box. In particular, the lead frame may already have a three-dimensionally shaped geometry, so that corresponding components can be connected to one another in an electrically conductive manner by means of the lead frame in a particularly simple and particularly automated manner.

Another possible embodiment of the invention provides that the electrical conductors of the leadframe are encapsulated, in particular injection-molded, with a thermally conductive and electrically insulating plastic. The coating with plastic can simultaneously achieve two functions: first, the plastic encases the individual electrical conductors that are used to electrically isolate the lead frames involved. Secondly, the injection-molded plastic can also help to stabilize the individual conductors and thus the entire leadframe, i.e. the leadframe of the connecting device. As mentioned above, the electrical conductor may have a three-dimensionally shaped contour according to its connecting task. By injection-molding the shape in plastic, it is possible to support the shape in a particularly simple and reliable manner. This facilitates handling of the lead frame, since the lead frame is much less sensitive to deformation than if the electrical conductors were not over-molded or wrapped with plastic.

A further possible embodiment of the invention provides that the at least one pre-mounted component is a component carrier, in particular made of plastic, in which and/or on which the at least one component is mechanically fixed and/or supported by at least one further pre-mounted component. Thereby, one or more components can be mechanically fixed and/or supported in a particularly simple and reliable manner. The component carrier can, for example, have a correspondingly shaped recess into which the component in question can be inserted at least partially, so that the component is mechanically fixed and/or supported. Thus, the component support helps to support and secure the individual components in their prescribed arrangement.

According to a further possible embodiment of the invention, it is provided that one of the premounted assemblies comprises control electronics which are electrically conductively connected to one or more components of the other premounted assembly. This control electronics may comprise, for example, a so-called Battery Management Controller (BMC). Furthermore, the control electronics may be provided with a housing to protect it from the environment. For example, during the switch box installation process, the control electronics may be installed as the last of the pre-installed components. Of course, a different order is possible.

A further possible embodiment of the invention provides that one of the preassembled components has at least one connection interface for a battery of the motor vehicle or a high-voltage vehicle electrical system, which is electrically conductively connected to one of the current rail sections. The pre-installation assembly can also have a plurality of such connection interfaces, so that, for example, the battery unit can be connected to the high-voltage vehicle electrical system of the motor vehicle via the installed switch box.

The switch box according to the invention for an electrically driven motor vehicle, in particular a high-voltage switch box, comprises a plurality of pre-installed assemblies with corresponding components, wherein the pre-installed assemblies are stacked one above the other in layers in a single installation direction and are connected to one another. In particular, the individual components of the pre-assembly can be arranged, shaped and oriented relative to one another such that the individual pre-assembly must be moved relative to one another only in a single installation direction according to a settable sequence in order to assemble the switch boxes in layers. Advantageous versions of the method according to the invention are to be regarded as advantageous versions of the switch box according to the invention and vice versa.

Further advantages, features and details of the invention emerge from the following description of preferred embodiments and the accompanying drawings. The features and combinations of features mentioned above in the description and those described below in the figures and/or shown in the figures only can be used not only in the respectively given combination but also in other combinations or alone without departing from the scope of the invention.

Drawings

The figures are as follows:

fig. 1 shows a schematic side view of a high-voltage switch box for an electrically driven vehicle;

fig. 2 shows a perspective view of the cooling plate of the high-voltage switch box from below;

fig. 3 shows a perspective view of the cooling plate from above;

fig. 4 shows a perspective view of a ground rail composite of a high-voltage switch box with a plurality of current rail sections, viewed from obliquely above;

fig. 5 shows a further perspective view of the ground rail assembly, wherein the individual rail sections are injection-molded with plastic;

fig. 6 shows another perspective view of the ground rail assembly after injection molding with plastic, in which current and voltage sensors and high-voltage contactors are also installed;

fig. 7 shows a perspective view of the positive current rail composite of the high-voltage switch box, viewed from obliquely above, before the respective current rail sections are connected to one another;

fig. 8 shows a perspective view of the positive current rail composite, seen from obliquely above, after injection-moulding of the current rail section with plastic;

FIG. 9 shows a perspective view from obliquely above of a positive rail composite with a pyrotechnic separation element, a fuse and a high-voltage contactor mounted in addition to a plastic encapsulation;

fig. 10 shows a perspective view of the cooling plate assembly connected to two current rail composites, viewed from obliquely above;

fig. 11 shows a top view of a partially installed high-voltage switch box with a plurality of lead frames, pre-charge circuits and temperature sensors in addition to the assembly of the cooling plate and current rail composite; and is

Fig. 12 shows a perspective view of an almost completely mounted high-voltage switch box with further control electronics also mounted.

In the figures, identical or functionally identical elements are provided with the same reference numerals.

Detailed Description

Fig. 1 shows a high-voltage switch box 10 for an electrically driven motor vehicle in a schematic and partial side view. The high-voltage switch box 10 comprises control electronics 12, which control electronics 12 may be, for example, a circuit board that functions as a so-called Battery Management Controller (BMC). In addition, the high-voltage switch box 10 comprises a component carrier 14 serving as a holding structure, for example for receiving the control electronics 12. The high-voltage switching box 10 also has one or more low-voltage contacts 16, a further component carrier 18 serving as a holding structure, a positive rail composite 20 serving as a positive pole path, a ground rail composite 22 serving as a negative pole path, a sealing compound 24 and a cooling plate 26. The high-voltage switch box 10 also has a plurality of different components 28, only one of which is shown schematically here.

To produce the high-voltage switchgear cabinet 10, the individual components 28 of the high-voltage switchgear cabinet 10 are matched to the respective pre-installed components. Here, the pre-mounted components are the control electronics 12, the component carrier 14, the component carrier 18, the low-voltage contact 16, the current rail composite 20, the current rail composite 22, and the cooling plate 26. Upon such mating, the individual components 28 are pre-mounted to the respective pre-mounted assemblies. The actual installation of the high-voltage switch box 10 is then carried out by assembling the pre-installed components together in layers one behind the other in a single installation direction 30. The individual pre-mounted assemblies and the associated components 28 or members are explained in more detail with reference to the following figures.

In fig. 2, the cooling plate 26 is shown in a perspective view from below. The cooling plate 26 may be made of aluminum, for example, by roll bonding or a hollow chamber process, wherein the cooling plate 26 preferably has a geometry optimized for coolant flow. Furthermore, the cooling plate 26 has been coated with a thermally conductive and electrically insulating plastic 32, for example by injection molding the cooling plate 26 with the plastic 32. Furthermore, a connection 34 of the cooling plate 26 is also visible, which serves as an inflow or outflow for the cooling medium.

In fig. 3, the cooling plate 26, which is coated or injection-molded with plastic 32, is visible in a perspective view from above. The upper side, which is visible here, formed by the plastic 32 serves as a heat transfer surface, so that excess energy can be transferred from the various components or components of the high-voltage switchgear cabinet 10 to the cooling medium flowing through the cooling plate 26.

In fig. 4, the ground rail composite 22, which serves as a negative pole path, is shown in perspective from obliquely above and before its individual current rail sections 36 have been connected to one another. Thus, the ground rail composite 22 is in the present case loosely preassembled. The individual current rail sections 36 can be produced, for example, by a stamping-bending process. This ground rail composite 22 is used for the high-voltage contacts of the high-voltage switch box 10 after production.

In fig. 5, the ground rail composite 22 is shown in a further perspective view from above. The conductor track sections 36, which are only partially visible here, are positioned relative to one another in their intended arrangement according to the illustration in fig. 4 and are coated, in particular injection-molded, with a thermally conductive and electrically insulating plastic 38. The individual current rail sections 36 serving as current rails have therefore already been positioned matched to one another, but have not yet been brought into electrically conductive contact with one another or at least not yet been soldered to one another. A different receiving region 40 for a high-voltage contact, not shown here, is formed by the plastic 38, which receiving region 40 can be brought into electrically conductive contact with the corresponding current rail section 36. The current rail sections 36, which are positioned relative to one another in the arrangement set or specified thereby, are fixed relative to one another by injection molding with plastic 38.

A plurality of free cuts, which are not labeled here in detail, can be provided in the plastic 38 in order to ensure access to the different welding zones. This simplifies the electrically conductive contacting or soldering of the individual current rail sections 36 to one another and also the electrically conductive connection of various components, not shown here, to the current rail sections 36.

In fig. 6, the ground rail composite 22 is shown in a further perspective view from obliquely above. The ground rail composite 22 is equipped with a current and voltage sensor 42 and two high voltage contactors 44. These

components

42, 44 are connected in an electrically conductive manner to the respective current rail section 36. This may be done by a suitable hot-splicing process, for example by means of laser welding. The individual current rail sections 36 are electrically conductively connected to one another by means of a suitable thermal joining method, for example also by laser welding. For this purpose, copper pins not shown here may also be used.

In fig. 7, the positive current rail composite 20 serving as the positive electrode path is shown in perspective from obliquely above, and before the respective current rail sections 46 have been fixed to one another. The individual current rail sections 46 serving as current rails are therefore still present in a loosely assembled manner and are only positioned relative to one another in their intended arrangement.

The positive current rail composite 20 is shown in fig. 8 in a further perspective view and after the individual current rail sections 46 have been injection-molded with a thermally conductive and electrically insulating plastic 48. This plastic in turn ensures that the current rail sections 46, which are positioned relative to one another in their intended arrangement, are held in this position in a fixed manner relative to one another. The plastic 48 can in turn be torn off or removed at the corresponding locations, so that the current rail sections 46 can be welded to one another in a particularly simple manner, and therefore individual components not illustrated here can be contacted to the current rail sections 46 particularly easily.

In fig. 9, the positive current rail composite 20 is shown in a further perspective view from obliquely above. The positive rail composite 20 is equipped with various components in the form of a pyrotechnic separation element 50, a plurality of safety devices 52 and a high-voltage contactor 44 by means of a suitable thermal splicing method, for example again by means of laser welding. The individual current rail sections 46 can in turn be connected by means of laser welding, wherein this can also be achieved by means of copper pins, which are not shown in detail.

Fig. 10 shows an assembly 54 in a perspective view from obliquely above, which assembly 54 comprises the cooling plate 26 and the

current rail composite

20, 22 equipped with corresponding components not shown in detail here. The mechanical connection, not shown here, between the cooling plate 26 and the

current rail composite

20, 22, not shown in detail, can be produced, for example, by screwing in injection bolts, form-fitting latching and/or other suitable methods.

Fig. 11 shows an assembly 56 in a top view, which assembly 56 has further components and connecting elements in addition to the assembly 54 shown in fig. 10. The positive rail composite 20, which is not illustrated in detail here, is provided with a temperature sensor 58. Furthermore, a plurality of lead frames 60 are provided, which serve as electrically conductive connecting means, said lead frames 60 forming in their entirety the low-voltage contacts 16 described in connection with fig. 1. The individual lead frames 60 comprise respective wires 62, which wires 62 are not fully depicted here for the sake of clarity. The individual lines 62 of the leadframe 60 are covered with a thermally conductive and electrically insulating plastic, not shown in detail, which can be achieved, for example, by injection molding the individual lines 62 with the plastic.

The assembly furthermore comprises a further lead frame 64 with corresponding wires 66, which for the sake of clarity are also not all drawn. These lead frames 64 are used for high-voltage measurements and are connected in an electrically conductive manner to the respective

current rail sections

36, 46 of the

current rail composites

20, 22. The lead frame 64 is thus used for high-voltage contacting within the high-voltage switch box 10. In addition, a partially visible pre-charge relay 68 is added.

The assembly 56 also comprises a plurality of connection interfaces 70, by means of which connection interfaces 70 the mounted high-voltage switch box 10 can be connected to the battery unit or the high-voltage on-board electrical system of the vehicle in question. The

component holders

14, 18 described in connection with fig. 1 for receiving and/or supporting the various components of the high-voltage switch cabinet 10 are not shown here.

In fig. 12, the high-voltage switch box 10 is shown in perspective view from obliquely above, almost completely installed. To this end, control electronics 12 are also added to the assembly 56 shown in fig. 11, said control electronics 12 being designed as a circuit board for the battery management controller. The

component holders

14, 18 serving as holding structures are also not shown here. The housing of the control electronics 12 is also not shown here. Finally, the remaining cable groups, which are not illustrated in detail here and may be present, are connected and corresponding electrical connections are produced between the lead frames 60, 64, the control electronics 12, the current and voltage sensors 42, the monitoring circuit, which is not illustrated in detail here, and the individual interfaces, not illustrated in detail, of the pyrotechnic separating elements 50, which are usually referred to as high-voltage interlock circuits.

When manufacturing the high-voltage switch box 10, and in particular when installing the high-voltage switch box 10, it is important to adapt the respective pre-installed components for the individual components of the high-voltage switch box 10. Then, each component is pre-mounted to the corresponding pre-mounted assembly according to the matching. Such a layout or matching according to the

pre-mounted components

12, 14, 16, 18, 20, 22, 26 is schematically illustrated in fig. 1.

After the pre-mounted components have been pre-mounted, the high-voltage switch box 10 is actually mounted by successively arranging the pre-mounted components one above the other in a single possible mounting direction 30 (see fig. 1) and assembling step by step. The layered structure shown in fig. 1 and the components of the high-voltage switch cabinet 10 mentioned in connection with fig. 2 to 12 are to be understood as exemplary only. What is important is the modular and hierarchical structure of the pre-installed components in one installation direction 30. The high-voltage switch box 10 has a standardized layout which is independent of its exact structure with regard to the individual components and which is designed for optimized production. Mechanized and automated manufacturing and installation is significantly facilitated by the bundling and prefabrication and pre-installation of the individual pre-installed components, followed by splicing and layer-by-layer installation. The production and assembly of the high-voltage switchgear cabinet 10 can therefore take place in a standardized production sequence, for example along an automated assembly line.

List of reference numerals

10 high-voltage switch box

12 control electronics

14 parts rack

16 low-voltage contact

18 parts rack

20 positive electrode current rail composite member

22 ground current rail composite

24 gap filling glue

26 Cooling plate

28 parts

30 direction of installation

32 plastics on Cooling plates

34 cooling plate connection part

Current rail section of 36 grounding current rail composite part

Plastic on 38 ground current rail covering piece

40 gap

42 current and voltage sensor

44 high-voltage contactor

Current rail section of 46 positive current rail composite part

Plastic on 48-anode current rail composite part

50 pyrotechnic separating element

52 safety device

54 assembly

56 assembly parts

58 temperature sensor

60 lead frame

62 lead of lead frame

64 lead frame

66 lead of lead frame

68 precharge relay

70 connecting interface

Claims

1. Method for producing a switch box, in particular a high-voltage switch box (10), for an electrically driven motor vehicle, comprising the following steps:

-matching respective pre-mounted assemblies (12, 14, 16, 18, 20, 22, 26) for respective components (28, 42, 44, 50, 52, 58, 68) of the switch box;

-pre-mounting the components (28, 42, 44, 50, 52, 58, 68) to the respective pre-mounted assemblies (12, 14, 16, 18, 20, 22, 26) according to the matching;

-mounting the switch box by assembling the pre-mounted assemblies (12, 14, 16, 18, 20, 22, 26) together in layers one after the other in a unique mounting direction (30).

2. Method according to claim 1, characterized in that the assembly of the pre-mounted components (12, 14, 16, 18, 20, 22, 26) is performed in an automated manner.

3. Method according to claim 1 or 2, characterized in that at least one of the pre-mounted assemblies comprises a current rail composite (20, 22), which current rail composite (20, 22) is pre-mounted in an electrically conductive manner by individual current rail sections (36, 46) and is equipped, in particular automatically, with at least one of the components (42, 44, 50, 52).

4. Method according to claim 3, characterized in that the current rail sections (36, 46) are positioned in a defined arrangement relative to one another and are coated, in particular injection-molded, with a thermally conductive and electrically insulating plastic (38, 48), and then are electrically conductively connected to one another.

5. Method according to claim 4, characterized in that after coating with the plastic (38, 48), the plastic is removed at set positions and there the current rail sections (36, 46) are brought into contact with each other or at least one of the components (42, 44, 50, 52) is brought into contact on one of the current rail sections (36, 46).

6. Method according to any one of the preceding claims, characterized in that at least one of the pre-mounted components is a cooling plate (26), through which cooling plate (26) a cooling medium can flow, which is pre-mounted and coated, in particular injection-molded, with a thermally conductive and electrically insulating plastic (32).

7. Method according to any of the preceding claims, characterized in that at least some of the components (28, 42, 44, 50, 52, 58, 68) are mutually conductively connected by means of at least one electrically conductive connecting device, which connecting device comprises a lead frame (60, 64) with a plurality of electrical conductors (62, 66).

8. Method according to claim 7, characterized in that the electrical conductor (62, 66) is coated, in particular injection-molded, with a thermally conductive and electrically insulating plastic.

9. Method according to one of the preceding claims, characterized in that at least one of the pre-mounted assemblies is a component holder (14, 18), in particular a component holder made of plastic, in and/or on which at least one of the components (28, 42, 44, 50, 52, 58, 68) of at least one further pre-mounted assembly (28, 42, 44, 50, 52, 58, 68) is mechanically fixed and/or supported.

10. Method according to any of the preceding claims, characterized in that one of the pre-mounted assemblies comprises control electronics (12) which are electrically conductively connected with one or more components (28, 42, 44, 50, 52, 58, 68) of a further pre-mounted assembly (14, 16, 18, 20, 22, 26).

11. Method according to one of claims 3 to 10, characterized in that one of the subassemblies (12, 14, 16, 18, 20, 22, 26) has at least one connection interface (70) for a battery of the vehicle or a high-voltage on-board electrical system, which is electrically conductively connected to one of the current rail sections (36, 46).

12. A switch box, in particular a high-voltage switch box (10), for an electrically driven motor vehicle, comprising a plurality of pre-mounted assemblies (12, 14, 16, 18, 20, 22, 26) with corresponding components (28, 42, 44, 50, 52, 58, 68), wherein the pre-mounted assemblies (12, 14, 16, 18, 20, 22, 26) are stacked one above the other in layers in a single mounting direction (30) and are connected to one another.