CN219536582U - Small-sized wire-free harness control box - Google Patents

Abstract

The utility model discloses a small-sized wire-free harness control box, which comprises: the control box comprises a first relay without a mounting shell, a control box shell and at least one pair of current-carrying copper bars fixed on the control box shell, wherein a containing cavity matched with the first relay in size is formed in the control box shell, and the first relay is mounted in the containing cavity and fixed with the current-carrying copper bars; the first relay is provided with a coil leading-out needle which extends into the control box shell and forms a relay connector on the control box shell, and the relay connector is used for being electrically connected with an external connector. The utility model not only can realize the purposes of small integration and wireless beam formation of the control box, but also has low cost and simple assembly process, is beneficial to batch automatic production and realizes cost reduction and efficiency improvement.

Description

Small-sized wire-free harness control box

Technical Field

The utility model relates to the technical field of control boxes, in particular to a small-sized wire-free wiring control box.

Background

At present, a plurality of wire harnesses are used for a control box product in a new energy battery pack and used for a relay coil control wire harness, a high-voltage loop voltage sampling wire harness and the like, the wire harnesses are arranged in disorder, and the insulation skin of the wire harnesses is also very easy to receive the extrusion of devices in the box and the cut of sharp parts; meanwhile, the wire harness is complex to assemble, the bad situations of misconnection and missed connection are very easy to occur, and after the control box with the wire harness is used for a period of time, the resistance value of the conductive connection part is increased due to the reasons of wire harness pulling, wire harness aging, joint loosening and the like, so that the heat is increased, equipment failure is light, and even a loop is disconnected or the loop is burnt out in a thermal runaway manner.

In addition, since the new energy automobile is insufficient in installation space of the battery pack and has higher and higher requirements on cruising ability of the battery pack, it is desirable to make the battery pack have multiple battery cores as much as possible, so that the energy density is continuously improved, and therefore the available space of the control box in the battery pack is reserved for recompression. In view of the foregoing, there is a strong need for a compact wireless networking control box.

Disclosure of Invention

The utility model aims to solve the problem of providing a small-sized wireless harness control box so as to overcome the defects of large volume, low space utilization rate and adverse effects caused by more harnesses in the conventional control box.

The technical scheme adopted by the utility model for solving the technical problems is as follows: a compact wireless harness control box comprising: the control box comprises a first relay without an installation shell, a control box shell and at least one pair of current-carrying copper bars fixed on the control box shell, wherein an accommodating cavity matched with the first relay in size is formed in the control box shell, and the first relay is installed in the accommodating cavity and fixed with the current-carrying copper bars; the first relay is provided with a coil leading-out needle which extends into the control box shell and forms a relay connector on the control box shell, and the relay connector is used for being in opposite insertion with an external connector.

As a further improvement of the utility model, the small-sized wireless wiring control box further comprises sampling copper bars which are electrically connected with the current-carrying copper bars in a one-to-one correspondence manner, wherein the sampling copper bars are used for collecting voltages at two ends of the first relay so as to obtain the on-off state of the first relay.

As a further improvement of the utility model, one end of the sampling copper bar is fixed on the current-carrying copper bar, and the other end of the sampling copper bar is provided with a sampling lead-out needle which extends into the control box shell and forms a sampling connector on the control box shell.

As a further improvement of the utility model, a relay coil power supply socket and a sampling socket are arranged at the side of the bottom of the control box shell, which is positioned beside the accommodating cavity, and the relay coil power supply socket is used for being matched and plugged with an external connector, the coil leading-out needle stretches into the relay coil power supply socket to form the relay connector, and the sampling leading-out needle stretches into the sampling socket to form the sampling connector.

As a further development of the utility model, the current-carrying copper bars are injection-molded in one piece with one another in the control box housing.

As a further improvement of the utility model, the current-carrying copper bar is provided with a middle section, a first connecting section and a second connecting section, the middle section is coated in the control box shell, the first connecting section is exposed out of the top of the accommodating cavity, the first relay is provided with two main contacts, and the two main contacts are locked on the current-carrying copper bar in a one-to-one correspondence manner by adopting a welding mode or using a first bolt; the second connection sections are provided with connection interfaces for accessing the electric loop.

As a further improvement of the present utility model, the small-sized wireless modular control box further includes a second relay mounted on the control box housing, the second relay having a pair of coil lead-out pieces and a pair of contact lead-out pieces, the coil lead-out pieces and the contact lead-out pieces being respectively connected with lead-out copper bars.

As a further improvement of the utility model, the coil lead-out sheet, the contact lead-out sheet and the lead-out copper bars are connected by adopting quick-plug switching terminals.

As a further improvement of the utility model, the quick-connect connection terminal is provided with a plug-in main body part with a hollow cavity, a side wall of the plug-in main body part is integrally connected with a clamping arm with elastic deformation capability, the clamping arm is bent into the cavity of the plug-in main body part to separate a slot in the cavity, and the coil lead-out sheet/the contact lead-out sheet and the lead-out copper bar are inserted into the slot from the same end or opposite ends of the quick-connect connection terminal.

As a further development of the utility model, the second relay has a mounting housing, and the second relay is fastened to the control box housing by means of mounting feet provided on the mounting housing.

The beneficial effects of the utility model are as follows:

1) The utility model provides a small-sized wire-free wiring control box, which is characterized in that a first relay without an installation shell is integrated on a control box shell, so that the integration level of the control box is improved, the cost is reduced, the space utilization rate is improved, and the purpose of small-sized integration of the control box is realized;

2) According to the utility model, the current-carrying copper bars and the control box shell are integrally injection molded, so that the volume of a product is further reduced, the arrangement distance of the current-carrying copper bars can be reduced on the premise of ensuring electrical safety, the risks of more and wrong assembly of conventional bulk copper bars are avoided, and the structural strength of the product can be improved;

3) According to the utility model, the sampling copper bar and the current-carrying copper bar are adopted for locking, the traditional high-voltage sampling by using the wire harness is replaced, the purpose of harness-free is realized, the connection is safer and more reliable, the assembly process is simple, and the risk of damage to the assembly of the conventional wire harness is avoided;

4) According to the utility model, the coil leading-out needle on the first relay extends into the control box shell to form a relay connector, and the sampling leading-out needle on the sampling copper bar extends into the control box shell to form a sampling connector, so that the conventional connector shell parts can be omitted, the cost is reduced, the integration level of the control box is improved, the space utilization rate is improved, and the purpose of small integration is further realized;

5) According to the utility model, the coil leading-out sheet and the contact leading-out sheet of the second relay are matched with the leading-out copper bar by adopting a fast-plug switching terminal to realize fast-plug connection, so that the mode of conventional connection by using a wire harness terminal is avoided, wire harness-free is further realized, and the connection is safer and more reliable;

6) The utility model has the advantages of low cost, simple assembly process, contribution to batch automatic production and realization of cost reduction and efficiency improvement.

Drawings

FIG. 1 is a perspective view of a compact wireless harness control box of the present utility model;

FIG. 2 is a perspective view of the compact wireless harness control box of the present utility model from another perspective;

FIG. 3 is a cross-sectional view of a compact wireless harness control box of the present utility model;

FIG. 4 is a perspective view of the compact wireless unified pod of the present utility model with the control pod housing removed;

FIG. 5 is a perspective view of the control box housing of the compact wireless modular control box of the present utility model;

FIG. 6 is a perspective view of a second relay, lead copper bars and quick connect terminals according to the present utility model;

FIG. 7 is a perspective view of a quick connect switch terminal according to the present utility model;

fig. 8 is a cross-sectional view of a quick connect terminal according to the present utility model.

The following description is made with reference to the accompanying drawings:

1. a first relay; 101. a coil lead-out needle; 2. a control box housing; 201. a receiving chamber; 202. the relay coil is powered by the power supply socket; 203. sampling the inserting groove; 3. current-carrying copper bars; 301. an intermediate section; 302. a first connection section; 303. a second connection section; 4. sampling a copper bar; 401. sampling leading-out needles; 5. a first bolt; 6. a connection interface; 7. a second relay; 701. a mounting foot; 8. leading out copper bars; 9. a quick-plug switching terminal; 901. a plug main body portion; 902. a clamping arm; 903. a slot.

Detailed Description

The preferred embodiments of the present utility model will be described in detail below with reference to the accompanying drawings.

Referring to fig. 1 to 8, the present utility model provides a small-sized wireless harness control box, comprising: a first relay 1 without a mounting housing, a control box housing 2, and at least one pair of current carrying copper bars 3 fixed to the control box housing 2. A bottomless accommodating cavity 201 is arranged in the control box shell 2, and the size of the accommodating cavity 201 is matched with the size of the first relay 1 without the mounting shell, so that the first relay 1 can be mounted in the accommodating cavity 201 from bottom to top. Wherein, the control box shell 2 is located in the accommodating cavity 201 and is further provided with a rib, a step and other structures for limiting the first relay 1 installed in the accommodating cavity 201. The utility model adopts the structure to omit the parts of the mounting shell of the conventional relay, and adopts the control box shell 2 to directly serve as the shell of the first relay 1, thereby reducing the cost, improving the integration level of the control box, improving the space utilization and realizing the purpose of small integration of the control box.

It should be noted that, the number of the first relays 1 installed on the control box housing 2 is determined according to the actual requirement of the application working condition and the size of the control box housing 2, and the specific number of the first relays 1 is not limited in the present utility model. In this embodiment, two first relays 1 are taken as an example to describe in detail, where the two first relays 1 are respectively used as a main positive relay and a main negative relay, and can load a large current, and can be used for controlling on-off of the battery pack dry circuit current. Correspondingly, two accommodating cavities 201 are arranged on the control box shell 2, and two pairs of current-carrying copper bars 3 are arranged on the control box shell.

Further, two pairs of current-carrying copper bars 3 are mutually insulated and integrally molded in the control box shell 2, two main contacts are arranged at the top of the first relay 1, and the first relay 1 is locked on the current-carrying copper bars 3 by using first bolts 5 in one-to-one correspondence on the two main contacts.

Specifically, the current-carrying copper bars 3 are all Z-shaped, and each Z-shaped copper bar has a middle section 301 vertically distributed, a first connecting section 302 and a second connecting section 303 transversely distributed, the first connecting section 302 is connected to the upper end of the middle section 301, the second connecting section 303 is connected to the lower end of the middle section 301, and the middle section 301 is wrapped in a side wall of the control box casing 2. The first connection section 302 extends towards the top of the accommodating cavity 201 and is exposed out of the control box housing 2, and the first connection section 302 is provided with a mounting hole. Screw holes are formed in the two main contacts of the first relay 1, the two main contacts of the first relay 1 installed in the accommodating cavity 201 are respectively abutted against the bottoms of the two first connection sections 302, the screw holes are arranged opposite to the mounting holes one by one, and then the first bolts 5 penetrate through the mounting holes to be locked in the screw holes, so that fixed connection between the first relay 1 and the corresponding current-carrying copper bars 3 is achieved. Of course, the two main contacts of the first relay 1 may also be fixedly connected to the current-carrying copper bar 3 by welding. The top of the second connection section 303 is fixed with a connection interface 6 wrapped by the control box housing 2, the bottom of the second connection section 303 is exposed out of the control box housing 2, and a through hole leading to the connection interface 6 is formed, so that the connection interface 6 is convenient to access the circuit. According to the utility model, the current-carrying copper bars 3 and the control box shell 2 are integrally injection molded, so that the volume of a product is further reduced, and compared with a bulk copper bar mode, the arrangement distance of the current-carrying copper bars 3 can be reduced on the premise of ensuring electrical safety, and the risks of more conventional bulk copper bars and wrong assembly are avoided; meanwhile, the current-carrying copper bar 3 and the control box shell 2 are integrated into a whole, so that the structural strength of the product can be improved.

Referring to fig. 2, a relay coil power supply socket 202 is disposed at the side of the accommodating cavity 201 at the bottom of the control box housing 2, coil lead pins 101 are disposed on the first relay 1, and the coil lead pins 101 are bent downwards to extend into the relay coil power supply socket 202 in the control box housing 2, so that a relay connector is formed on the control box housing 2, and the relay connector is used for being matched and plugged with an external connector to perform electrical connection so as to control power loss of the coil of the first relay 1. The utility model directly designs the connector shell of the conventional relay on the control box shell 2, namely the relay coil power supply socket 202, so that the connector shell part of the conventional relay can be omitted, the cost is reduced, the wire harness lead-out mode is replaced by the coil lead-out needle 101, the wire harness-free purpose is realized, the integration level of the control box is improved, the space utilization rate is improved, and the purpose of small integration is further realized.

Referring to fig. 1 to 5, the small-sized wireless wiring harness control box of the utility model further comprises four sampling copper bars 4 electrically connected with the current-carrying copper bars 3 in a one-to-one correspondence manner, wherein the four sampling copper bars 4 are used as a group for collecting voltages at two ends of the two first relays 1 respectively so as to obtain on-off states of the two first relays 1.

One end of each of the four sampling copper bars 4 is fixed on the current-carrying copper bar 3 in a one-to-one correspondence manner by using a second bolt, and the other end of each sampling copper bar is bent downwards and extends into the control box shell 2. The bottom of the control box shell 2 is located at the side of the accommodating cavity 201 and is further provided with two sampling inserting grooves 203 for being matched and inserted with an external connector, the other ends of the four sampling copper bars 4 are respectively provided with sampling lead-out needles 401, and the sampling lead-out needles 401 extend into the corresponding sampling inserting grooves 203, so that two sampling connectors are formed on the control box shell 2. According to the utility model, the sampling copper bar 4 and the current-carrying copper bar 3 are adopted for locking and connected, and the sampling connector is directly formed on the control box shell 2, so that the scheme of high-pressure sampling by using a conventional ring terminal belt wire harness is replaced, the purpose of harness-free is realized, the mode connection is safer and more reliable, the assembly process is simple, and the risk of damage to conventional harness assembly is avoided.

The control box housing 2 is provided with opposite insertion structures matched with external connectors, such as ribs, clamping grooves, bosses and the like, in the relay coil power supply inserting groove 202 and the sampling inserting groove 203, and is used for guiding, limiting, buckling and the like.

In general, the new energy battery pack control box is not only required to be provided with the main positive relay and the main negative relay, but also often provided with a small current load loop relay for on-off control of a small current load loop such as a pre-charging loop, a battery pack heating loop and the like. Therefore, the small-sized wireless-wired control box of the present utility model further includes the second relay 7 for the small-current load circuit. In this embodiment, the second relay 7 is sampled by integrally encapsulating epoxy sealant in its mounting housing, which is inconvenient for the integration of the shelling into the control box housing 2. Specifically, the second relay 7 is fixed to the control box housing 2 by mounting legs 701 provided on a mounting case thereof. The second relay 7 has a pair of coil lead-out pieces and a pair of contact lead-out pieces, each of which is connected with a lead-out copper bar 8, and is connected to the circuit via the respective lead-out copper bar 8.

Referring to fig. 6 to 8, the coil lead-out piece, the contact lead-out piece and the respective lead-out copper bars 8 are connected by using a quick-plug adapter terminal 9.

Specifically, the quick connector adapter terminal 9 is provided with a plug main body portion 901, and the plug main body portion 901 is in a frame shape with two ends penetrating up and down. The bottom of the front side wall of the plugging main body portion 901 is integrally connected with a clamping arm 902 with elastic deformation capability, the clamping arm 902 is bent into a cavity of the plugging main body portion 901 and extends upwards to separate the cavity from the slot 903, and the coil lead-out sheet/contact lead-out sheet and the lead-out copper bar 8 can be inserted into the slot 903 from the same end or opposite ends of the quick-plug adapter terminal 9. Specifically, in this embodiment, the clamping arm 902 separates the cavity into two slots 903, the coil lead-out sheet/contact lead-out sheet is inserted into one of the slots 903 from bottom to top, the lead-out copper bar 8 is inserted into the other slot 903 from top to bottom, so as to realize quick-plug connection, and the S-shaped clamping arm 902 is matched with the front side wall and the rear side wall to clamp the lead-out copper bar, so that the mode of conventionally using the wire harness terminal connection is avoided, wire-free wiring is realized, and the connection is safer and more reliable.

In the above description, numerous specific details are set forth in order to provide a thorough understanding of the present utility model. The foregoing description is only of a preferred embodiment of the utility model, which can be practiced in many other ways than as described herein, so that the utility model is not limited to the specific implementations disclosed above. While the foregoing disclosure has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes and modifications may be made and equivalents may be substituted for elements thereof without departing from the scope of the utility model. Any simple modification, equivalent variation and modification of the above embodiments according to the technical substance of the present utility model without departing from the technical solution of the present utility model still falls within the scope of the technical solution of the present utility model.

Claims (10)

1. A compact, wireless harness control box, comprising: the control box comprises a first relay (1) without a mounting shell, a control box shell (2) and at least one pair of current-carrying copper bars (3) fixed on the control box shell (2), wherein a containing cavity (201) with the size matched with that of the first relay (1) is arranged in the control box shell (2), and the first relay (1) is mounted in the containing cavity (201) and fixed with the current-carrying copper bars (3); the first relay (1) is provided with a coil leading-out needle (101), the coil leading-out needle (101) stretches into the control box shell (2) and forms a relay connector on the control box shell (2), and the relay connector is used for being electrically connected with an external connector in an opposite insertion mode.

2. The compact, wireless modular control cartridge of claim 1, wherein: the device further comprises sampling copper bars (4) which are electrically connected with the current-carrying copper bars (3) in a one-to-one correspondence manner, wherein the sampling copper bars (4) are used for collecting voltages at two ends of the first relay (1) so as to obtain the on-off state of the first relay (1).

3. The compact, wireless modular control cartridge of claim 2, wherein: one end of the sampling copper bar (4) is fixed on the current-carrying copper bar (3), the other end of the sampling copper bar is provided with a sampling lead-out needle (401), and the sampling lead-out needle (401) stretches into the control box shell (2) and forms a sampling connector on the control box shell (2).

4. A compact wireless harness control box as claimed in claim 3, wherein: the bottom of control box casing (2) is located the side of holding chamber (201) is provided with relay coil power supply grafting slot (202) and sampling grafting groove (203) that are used for cooperating grafting with external connector, thereby coil extraction needle (101) stretches into in this relay coil power supply grafting slot (202) and forms the relay connector, thereby sampling extraction needle (401) stretches into in sampling grafting groove (203) forms the sampling connector.

5. The compact, wireless modular control cartridge of claim 1, wherein: the current-carrying copper bars (3) are mutually insulated and integrally injection-molded in the control box shell (2).

6. The compact wireless harness control box of claim 5, wherein: the current-carrying copper bar (3) is provided with a middle section (301), a first connecting section (302) and a second connecting section (303), the middle section (301) is coated in the control box shell (2), the first connecting section (302) is exposed out of the top of the accommodating cavity (201), the first relay (1) is provided with two main contacts, and the two main contacts are locked on the current-carrying copper bar (3) in a one-to-one correspondence manner by adopting a welding mode or using a first bolt (5); the second connection sections (303) are each provided with a connection interface (6) for accessing the electrical circuit.

7. The compact, wireless modular control cartridge of claim 1, wherein: the control box further comprises a second relay (7) arranged on the control box shell (2), the second relay (7) is provided with a pair of coil leading-out sheets and a pair of contact leading-out sheets, and the coil leading-out sheets and the contact leading-out sheets are respectively connected with leading-out copper bars (8).

8. The compact wireless harness control box of claim 7, wherein: the coil leading-out sheet, the contact leading-out sheet and the leading-out copper bars (8) are connected by adopting quick-plug switching terminals (9).

9. The compact wireless harness control box of claim 8, wherein: the fast-plugging transfer terminal (9) is provided with a plugging main body part (901) with a hollow cavity, a clamping arm (902) with elastic deformation capability is integrally connected to one side wall of the plugging main body part (901), the clamping arm (902) is bent into the cavity of the plugging main body part (901) to separate a slot (903) in the cavity, and the coil leading-out sheet/the contact leading-out sheet and the leading-out copper bar (8) are inserted into the slot (903) from the same end or opposite ends of the fast-plugging transfer terminal (9).

10. The compact wireless harness control box of claim 7, wherein: the second relay (7) is provided with a mounting shell, and the second relay (7) is fixed on the control box shell (2) through a mounting foot (701) arranged on the mounting shell.