DE102019104962B4 - METHOD FOR PRODUCING A SWITCH BOX, IN PARTICULAR A HIGH VOLTAGE SWITCH BOX, FOR AN ELECTRICALLY DRIVEN MOTOR VEHICLE AND SWITCH BOX - Google Patents

Abstract

Method for producing a switch box, in particular a high-voltage switch box (10), for an electrically driven motor vehicle, comprising the steps: - Assigning individual components (28, 42, 44, 50, 52, 58, 68) of the switch box to respective pre-assembly groups (12, 14, 16, 18, 20, 22, 26);- Pre-assembling the components (28, 42, 44, 50, 52, 58, 68) to the respective pre-assembly brewing groups (12, 14, 16, 18, 20, 22, 26 ) according to the assignment; - Assembling the switch box by assembling the pre-assembled pre-assembly groups (12, 14, 16, 18, 20, 22, 26) one after the other in a single assembly direction (30), with at least one of the pre-assembly assemblies forming a busbar assembly (20 , 22), which is pre-assembled in an electrically conductive manner from individual busbar segments (36, 46) and equipped with at least one of the components (42, 44, 50, 52), in particular automatically equipped, and the busbar segments (36, 46) in one positioned relative to each other in the intended arrangement and encased, in particular overmolded, with a thermally conductive and electrically insulating plastic (38, 48), and then connected to one another in an electrically conductive manner, whereby after the encasement with the plastic (38, 48), it is removed at predetermined points and there the busbar segments (36, 46) are contacted with one another or the at least one component (42, 44, 50, 52) on one of the busbar segments (36, 46) is contacted.

Description

Technical area

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

State of the art

A high-voltage system, or high-voltage (HV for short), is an independent term from vehicle technology for systems that are operated with alternating voltages of over 30 V to 1 kV or with direct voltages of over 60 V to 1.5 kV. The term high voltage should not be confused with the term high voltage from electrical energy technology. Systems that are operated with alternating voltages in the vehicle sector up to and including 30 V or direct voltages up to and including 60 V are referred to as low-voltage systems or low-voltage (NV for short) and are primarily used in the vehicle electrical system. The distinction is particularly relevant for vehicles with electric drives such as hybrid vehicles, vehicles with fuel cells or batteries. A high-voltage switch box is therefore designed for correspondingly high voltages.

So-called high-voltage switch boxes serve as an interface between battery cells and the high-voltage electrical system in purely electrically powered motor vehicles or hybrid vehicles. In other words, high-voltage switch boxes serve as an interface between the battery cells of a storage system and the high-voltage electrical system of a motor vehicle. High-voltage switch boxes usually include separating elements, fuses, high-precision measurement technology and safety-relevant and relatively complex control electronics.

A central element of such high-voltage switch boxes is usually the battery control unit, which records all relevant data from the battery system, such as a current and/or voltage sensor or the cell controller. One or more current-voltage sensors usually determine precise data for battery management and provide a very precise determination of the state of charge of the high-voltage battery and thus the range of the vehicle in question. In addition to the current-voltage sensor, the high-voltage switch box usually also contains the control for an electric heater of the high-voltage storage unit in question as well as other electrical components that are responsible for opening and closing the high-voltage current paths, the controlled starting of the vehicle in question and protection in the event of a fault .

Due to the increasing electrification of automobiles, the complexity of the components in electric vehicles and hybrid vehicles is constantly increasing. This presents the automotive industry with a continuous learning and optimization process because the necessary experience must first be gained. When analyzing switch boxes or high-voltage switch boxes, it becomes clear that they have to take on additional functions for use in electric vehicles. Among other things, the safety of the people being transported and the monitoring of the battery compared to its counterparts for internal combustion engines must be taken into account.

Usually, the production and in particular the assembly of such switch boxes - especially due to their complexity and their vehicle-specific development - is still largely carried out manually. Reasons for this can, for example, be non-ideal installation space specifications, which in turn can result in unfavorable assembly conditions for the design of the busbars of the switch boxes. In addition, when assembling such switch boxes, it is often necessary to provide a variety of assembly and screwing directions and to provide a relatively small cable set for cabling sensors, actuators and other components.

Therefore, respective components of a switch box to be manufactured are arranged individually for each vehicle and connected to appropriately designed busbars. The vehicle-specific arrangement of the components usually results in a large number of assembly and screwing directions, which makes automated assembly difficult or impossible. The same applies to the assembly of the cable set on such switch boxes, the small-scale complexity of which cannot be economically automated and which also places enormous demands on manual assembly in terms of error rates. In addition, the vehicle-specific design of such switch boxes requires new tests for each model with regard to functional load capacity, crash stability and electromagnetic compatibility, so that such tests can incur enormous costs.

The publication DE 11 2013 004 237 T5 describes an electronic circuit device configured to transmit a direct current via a DC bus bar to an electronic circuit component such as a converter device for converting a direct current to an alternating current.

The publication DE 10 2017 116 724 A1 describes a method for producing several busbar assemblies.

Description of the invention

It is therefore the object of the present invention 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 motor vehicle is made possible.

This object is achieved by a method for producing a switch box, in particular a high-voltage switch box, for an electrically powered motor vehicle. Further possible embodiments of the invention are specified 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 motor vehicle, individual components of the switch box are assigned to respective pre-assembly assemblies. The components are pre-assembled into the respective pre-assembly assemblies according to the assignment. The switch box is then assembled by assembling the pre-assembled pre-assembly assemblies one after the other in a single assembly direction, one after the other. At least one of the pre-assembly assemblies comprises a busbar assembly, which is preassembled in an electrically conductive manner from individual busbar segments and equipped with at least one component, in particular automatically equipped. The busbar segments are positioned in a proper arrangement relative to one another and are encased, in particular overmolded, with a thermally conductive and electrically insulating plastic, and then connected to one another in an electrically conductive manner. After being covered with the plastic, it is removed at predetermined points and there the busbar segments are contacted with each other or the at least one component on one of the busbar segments is contacted.

Assembling together means in particular that the individual pre-assembly assemblies are connected to one another, for example in a positive and/or non-positive manner. In particular, it is intended that when producing the switch box, a standardized layout is specified for the switch box, which enables the production or production of large quantities at low unit prices. Furthermore, due to the standardized layout of the switch box, the cost-intensive, comprehensive tests mentioned at the beginning to ensure readiness for series production are not necessary for every model. It is also possible to incorporate a standardized switch box as an integral part of a modular high-voltage battery.

The invention can therefore also include a method for producing different variants of the switch box, in which case, in particular across variants, a standardized layout or a standardized basic structure is specified for all variants of the switch box. The various pre-assembly assemblies can, for example, be standardized according to functional aspects of the switch box. Within the individual pre-assembly assemblies, depending on the variant, it is then possible to vary the specific composition of the pre-assembly assemblies from individual components accordingly. The single assembly direction remains the same across all variants of the switch box, so that for all variants of the switch boxes to be manufactured, the pre-assembled pre-assembly assemblies can be assembled together in layers, one after the other, in a single direction.

For example, using the method it is also possible to produce scalable switch boxes, which can affect the scaling and dimensioning of individual components and/or the number of the respective components. In the method according to the invention, there is in particular a strict focus on optimized production of the switch box or the different switch box variants. This means that the effort involved in producing the switch box or the different switch box variants can be significantly reduced.

What is essential in the method according to the invention is the division of the components or individual components into said pre-assembly assemblies, which are pre-assembled separately. A modular and layered structure of the pre-assembly assemblies for the switch box in a single assembly direction enables standardized production of the switch box or different switch box variants. The individual pre-assembly assemblies are connected to one another using suitable joining methods, for example by screwing, welding, hot staking, soldering, laser bonding, positive locking and the like, to give just a few examples of possible joining methods.

In addition, when assembling the pre-assembly assemblies to the switch box, compensation for existing or emerging manufacturing and assembly tolerances is ensured. The configurations of the assembly of the pre-assembly assemblies and the entire switch box take into account in particular the requirements of an automated system Manufacturing as well as requirements for electromagnetic compatibility.

By means of the method according to the invention, it is therefore possible to produce a single switch box variant or different switch box variants in a particularly simple, standardized and therefore cost-effective manner. Both the production of the pre-assembly assemblies and the assembly into the finished switch box are optimized in particular for machine producibility and therefore enable the production and in particular the assembly of the switch box in a standardized manufacturing sequence, in particular in the form of an automated assembly line. It can therefore be provided that the assembly of the pre-assembled pre-assemblies is carried out automatically. As a result, using the method according to the invention, it is possible to produce a modular switch box that is scalable in terms of its scope of performance in a particularly simple and cost-effective manner. The assembly or production of the individual pre-assembly assemblies can also be automated, which means that manual work steps and the associated effort and costs can be saved.

In other words, the busbar network is a type of busbar package. It can be provided that respective busbar assemblies from the individual busbar segments are provided separately for a plus and ground connection. The assembly with parts or components, for example in the form of high-voltage contactors, fuses, pyrotechnic elements and the like, can be done automatically. In this way, it is possible to implement the busbar assembly in question as well as equipping the busbar assembly with corresponding parts or components in a particularly simple, standardized and cost-effective manner.

The busbar segments are positioned in a proper arrangement relative to one another and are encased, in particular overmolded, with a thermally conductive and electrically insulating plastic, and then connected to one another in an electrically conductive manner. In this way, the individual busbar segments can be fixed in their intended arrangement to one another by the plastic. In addition, the plastic can be coated or overmolded in such a way that, for example, receiving areas for different parts or components are provided, which can then be connected to the busbar segments in an electrically conductive manner. Because the busbar segments are positioned relative to one another in their intended arrangement and are then coated, in particular overmolded, with said plastic, it is possible to fix the busbar segments in their intended arrangement in a particularly simple and automated manner. This then facilitates the electrically conductive connection of the individual busbar segments to one another, which in turn can be carried out automatically.

After being coated with the plastic, it is removed at predetermined locations and there the busbar segments are contacted with one another and/or the at least one component on one of the busbar segments is contacted. In other words, it is possible, for example, for some free cuts to be provided in the plastic to create accessibility to welding zones or other fastening options, so that the busbar segments can be contacted with one another in a particularly simple manner and / or contacting parts or components on the busbar segments in particular can be done easily and reliably.

According to a further possible embodiment of the invention, it is provided that at least one of the pre-assembly assemblies is a cooling plate through which a cooling medium can flow, which is pre-assembled and encased, in particular overmolded, with a thermally conductive and electrically insulating plastic. The cooling plate can be made from aluminum, for example. In addition, it is possible, for example, to produce the cooling plate using a roll bond or hollow chamber process, whereby a flow-optimized channel geometry can be provided in the cooling plate. Because the cooling plate is encased, in particular overmolded, with the thermally conductive and electrically insulating plastic, it can be ensured on the one hand that good heat dissipation can take place via the cooling plate, while on the other hand it can be ensured that there are no short circuits between current-carrying components and the cooling plate comes.

A further possible embodiment of the invention provides that at least some of the components are electrically connected to one another by means of at least one electrically conductive connection arrangement, which comprises a lead frame with a plurality of electrical conductors. Several of these lead frames can also be provided in order, for example, to connect both high-voltage components and low-voltage components to one another in an electrically conductive manner. These lead frames with the multiple electrical conductors, which serve as electrically conductive connection arrangements, can Replace classic cable sets as far as possible or completely in the switch box. In particular, the lead frames can already have a three-dimensionally shaped geometry or shape, so that the corresponding components can be connected to one another in an electrically conductive manner in a particularly simple and, in particular, automated manner using the lead frames.

A further possible embodiment of the invention provides that the electrical conductors of the lead frame are encased, in particular overmolded, with a thermally conductive and electrically insulating plastic. The plastic coating can fulfill two functions at the same time: Firstly, the plastic coating serves to electrically insulate the individual electrical conductors of the lead frame in question. Secondly, the overmolded plastic can also contribute to stabilizing the individual conductors and thus the entire lead frame, i.e. the connection arrangement. As mentioned, the electrical conductors can have a three-dimensional contour depending on their connection task. This shape can be supported particularly easily and reliably by overmolding with the plastic. This makes it easier to handle the lead frames, as they are much less sensitive to deformation than if the electrical conductors were not overmolded or covered with the plastic.

A further possible embodiment of the invention provides that at least one of the pre-assembly assemblies is a component carrier, in particular made of plastic, in and/or on which at least one of the components of at least one of the other pre-assembly assemblies is mechanically fixed and/or supported. This allows one or more components to be mechanically fixed and/or supported in a particularly simple and reliable manner. The component carrier can, for example, have correspondingly shaped recesses into which the relevant components can be at least partially inserted, so that they are mechanically fixed and/or supported. The component carrier therefore helps to support and fix the individual components in their intended arrangement.

According to a further possible embodiment of the invention, it is provided that one of the pre-assembly assemblies comprises control electronics, which is connected in an electrically conductive manner to one or more components of the other pre-assembly assemblies. This control electronics can include, for example, a so-called Battery Management Controller (BMC). The control electronics can also be provided with an enclosure to protect it from environmental influences. For example, the control electronics can be installed as the last of the pre-assembly assemblies during the assembly of the switch box. A different order is of course also possible.

A further possible embodiment of the invention provides that one of the pre-assembly assemblies has at least one connection interface for a battery or a high-voltage electrical system of the motor vehicle, which is electrically connected to one of the busbar segments. Said pre-assembly assembly can also have several of these connection interfaces, so that battery cells, for example, can be connected to the high-voltage electrical system of the motor vehicle using the fully assembled switch box.

The switch box, in particular a high-voltage switch box, for an electrically driven motor vehicle comprises a plurality of pre-assembly assemblies with respective components, wherein the pre-assembly assemblies are arranged in layers one above the other in a single assembly direction and are connected to one another. The individual components of the pre-assembly assemblies can in particular be arranged, shaped and aligned with one another in such a way that the individual pre-assembly assemblies have to be moved towards one another exclusively in the single assembly direction in accordance with a predeterminable sequence in order to assemble the switch box in layers. Advantageous embodiments of the method according to the invention are to be viewed as advantageous embodiments of the switch box and vice versa.

Further advantages, features and details of the invention result from the following description of a preferred exemplary embodiment and from the drawing. The features and combinations of features mentioned above in the description as well as the features and combinations of features shown below in the description of the figures and/or in the figures alone can be used not only in the combination specified in each case, but also in other combinations or on their own, without the scope of the invention to leave.

Short character description

• 1 eine schematische Seitenansicht einer Hochvoltschaltbox für ein elektrisch angetriebenes Kraftfahrzeug;
• 2 eine Perspektivansicht von unten auf eine Kühlplatte der Hochvoltschaltbox;
• 3 eine Perspektivansicht von schräg oben auf die Kühlplatte;
• 4 eine Perspektivansicht von schräg oben auf einen mehrere Stromschienensegmente aufweisenden Masse-Stromschienenverbund der Hochvoltschaltbox;
• 5 eine weitere Perspektivansicht des Masse-Stromschienenverbunds, wobei die einzelnen Stromschienensegmente mit einem Kunststoff umspritzt wurden;
• 6 eine weitere Perspektivansicht des Masse-Stromschienenverbunds nach der Umspritzung mit dem Kunststoff, wobei zudem noch ein Strom- und Spannungssensor sowie Hochvolt-Schütze angebracht worden sind;
• 7 eine Perspektivansicht von schräg oben auf einen Plus-Stromschienenverbund der Hochvoltschaltbox, bevor jeweilige Stromschienensegmente miteinander verbunden worden sind;
• 8 eine Perspektivansicht von schräg oben auf den Plus-Stromschienenverbund nachdem die Stromschienensegmente mit einem Kunststoff umspritzt worden sind;
• 9 eine Perspektivansicht von schräg oben auf den Plus-Stromschienenverbund, nachdem zusätzlich zur Kunststoffumspritzung noch ein pyrotechnisches Trennelement, Sicherungen und Hochvolt-Schütze angebracht worden sind;
• 10 eine Perspektivansicht von schräg oben auf einen Zusammenbau der Kühlplatte mit den beiden Stromschienenverbunden;
• 11 eine Draufsicht auf die zum Teil fertig montierte Hochvoltschaltbox, welche neben dem Zusammenbau der Kühlplatte mit den Stromschienenverbunden unter anderem mehreren Stanzgitter, einen Vorladekreis und Temperatursensoren aufweist; und
• 12 eine Perspektivansicht auf die fast fertig montierte Hochvoltschaltbox, nachdem noch eine Steuerelektronik montiert worden ist.

It shows:

• 1 a schematic side view of a high-voltage switch box for an electrically powered motor vehicle;
• 2 a perspective view from below of a cooling plate of the high-voltage switch box;
• 3 a perspective view diagonally from above of the cooling plate;
• 4 a perspective view obliquely from above of a ground-busbar assembly of the high-voltage switch box having several busbar segments;
• 5 a further perspective view of the ground-busbar assembly, with the individual busbar segments being encapsulated with a plastic;
• 6 another perspective view of the ground-busbar assembly after the plastic has been encapsulated, with a current and voltage sensor and high-voltage contactors also being attached;
• 7 a perspective view from diagonally above of a plus busbar assembly of the high-voltage switch box before respective busbar segments have been connected to one another;
• 8th a perspective view diagonally from above of the plus busbar assembly after the busbar segments have been encapsulated with a plastic;
• 9 a perspective view from above diagonally of the plus busbar assembly after a pyrotechnic separating element, fuses and high-voltage contactors have been attached in addition to the plastic encapsulation;
• 10 a perspective view diagonally from above of an assembly of the cooling plate connected to the two busbars;
• 11 a top view of the partially assembled high-voltage switch box, which, in addition to the assembly of the cooling plate with the busbars, has, among other things, several lead frames, a pre-charging circuit and temperature sensors; and
• 12 A perspective view of the almost fully assembled high-voltage switch box after control electronics have been installed.

In the figures, identical or functionally identical elements have been given the same reference numerals.

A high-voltage switch box 10 for an electrically driven motor vehicle is shown schematically and in detail in a side view 1 shown. The high-voltage switch box 10 includes control electronics 12, which can be, for example, a circuit board that serves as a so-called battery management controller (BMC). In addition, the high-voltage switch box 10 includes a component carrier 14, which serves as a holding structure, for example for accommodating the control electronics 12. In addition, the high-voltage switch box 10 also has one or more low-voltage contacts 16, a further component carrier 18 serving as a holding structure, and a plus busbar assembly serving as a plus path 20, a ground busbar assembly 22 serving as a negative path, Gapfiller gel 24 and a cooling plate 26. Furthermore, the high-voltage switch box 10 has several different components 28, only one of which is shown schematically here.

To produce the high-voltage switch box 10, the individual components 28 of the high-voltage switch box 10 are assigned to respective pre-assembly assemblies. In the present case, the pre-assembly assemblies are the control electronics 12, the component carriers 14, 18, the low-voltage contacts 16, the busbar assemblies 20, 22 and the cooling plate 26. According to this assignment, the individual components 28 are pre-assembled into the respective pre-assembly assemblies. The actual assembly of the high-voltage switch box 10 then takes place by assembling the pre-assembled pre-assembly assemblies one after the other in a single assembly direction 30 in layers. The individual pre-assembly assemblies and the associated components 28 or components are explained in more detail using the following figures.

In 2 the cooling plate 26 is shown in a perspective view from below. The cooling plate 26 can be made, for example, from aluminum using a roll bond or hollow chamber process, with the cooling plate 26 preferably having a flow-optimized geometry for a coolant. Furthermore, the cooling plate 26 has been covered with a thermally conductive and electrically insulating plastic 32, for example by overmolding the cooling plate 26 with the plastic 32. Furthermore, connections 34 of the cooling plate 26 can be seen, which serve as an inflow or outflow for the cooling medium in question.

In 3 the cooling plate 26 coated or provided with the plastic 32 can be seen in a perspective view from above. The top side seen here, which is formed by the plastic 32, serves as a heat transfer surface, so that excess energy from various components of the high-voltage switch box 10 can be transferred to the cooling medium which flows through the cooling plate 26.

In 4 the ground-busbar assembly 22 serving as a negative path is shown in a perspective view obliquely from above, even before individual busbar segments 36 of the ground-busbar assembly 22 are connected to one another have been tied. In the present case, the ground busbar assembly 22 is still loosely pre-assembled. The individual busbar segments 36 can be manufactured, for example, using a punching-bending process. After completion, this ground busbar assembly 22 is used for high-voltage contacting of the high-voltage switch box 10.

In 5 the ground busbar assembly 22 is shown in another perspective view from above. The busbar segments 36, which are only partially visible here, were constructed as shown in 4 positioned in their intended arrangement relative to one another and coated, in particular overmolded, with a thermally conductive and electrically insulating plastic 38. The individual busbar segments 36 serving as busbars have already been positioned to match one another but have not yet made electrically conductive contact with one another or at least not yet been welded to one another. The plastic 38 forms various receiving areas 40 for high-voltage contactors, not yet shown here, which can be electrically contacted with the corresponding busbar segments 36. By encapsulating the plastic 38, the busbar segments 36 positioned relative to one another in their intended or intended arrangement are already fixed relative to one another.

Some free cuts (not marked here) can be provided within the plastic 38 in order to ensure accessibility to various welding zones. This facilitates the electrically conductive contacting or welding together of the individual busbar segments 36 and also the electrically conductive connection of various components (not shown here) to the busbar segments 36.

In 6 the ground busbar assembly 22 is shown in another perspective view obliquely from above. The ground busbar assembly 22 was equipped with a current and voltage sensor 42 and two high-voltage contactors 44. These components 42, 44 were electrically connected to the corresponding busbar segments 36. This can be done using suitable thermal joining processes, for example using laser welding. The individual busbar segments 36 were connected to one another in an electrically conductive manner using suitable thermal joining processes, for example also using laser welding. For example, copper pins (not shown here) can be used for this purpose.

In 7 the plus busbar assembly 20 serving as a plus path is shown in a perspective view obliquely from above, even before the respective busbar segments 46 have been attached to one another. The individual busbar segments 46 serving as busbars are still loosely assembled and have only been positioned in their intended arrangement relative to one another.

In 8th the plus busbar assembly 20 is shown in a further perspective view, namely after the individual busbar segments 46 have been encapsulated with a thermally conductive and electrically insulating plastic 48. This in turn ensures, among other things, that the busbar segments 46 positioned in their intended arrangement relative to one another are held fixed in this position relative to one another. The plastic 48 can also be exposed or removed at appropriate points so that the busbar segments 46 can be welded together particularly easily, for example, and so that a wide variety of components, not shown here, can be contacted particularly easily on the busbar segments 46.

In 9 the plus busbar assembly 20 is shown in another perspective view obliquely from above. The plus busbar assembly 20 was equipped with a wide variety of components in the form of a pyrotechnic separating element 50, several fuses 52 and high-voltage contactors 44 using suitable thermal joining processes, for example again using laser welding. The individual busbar segments 46 can in turn also be connected using laser welding, and this can also be done with the help of unspecified copper pins.

In 10 an assembly 54 is shown in a perspective view obliquely from above, which includes the cooling plate 26 and the busbar assemblies 20, 22 (not specified here) equipped with the respective components. A mechanical connection, not shown here, between the cooling plate 26 and the busbar connections 20, 22, which are not specified here, can be produced, for example, by screwing onto injected bolts, positive locking and/or other suitable methods.

In 11 an assembly 56 is shown in a top view from above, which is next to the one in 10 Assembly 54 shown has further components and connecting elements. The plus busbar assembly 20, which is not marked here, was provided with temperature sensors 58. In addition, several are considered electric rically conductive connection arrangements serving lead frames 60 are provided, which in their entirety are in connection with 1 mentioned low-voltage contact 16 form. The individual lead frames 60 include respective lines 62, not all of which have been marked here for the sake of clarity. The individual lines 62 of the lead frame 60 are encased in an unspecified thermally conductive and electrically insulating plastic; this can be achieved, for example, by overmolding the individual lines 62 with said plastic.

Furthermore, the assembly includes further lead frames 64 with respective lines 66, which in turn have not all been marked for the sake of clarity. These lead frames 64 are used for high-voltage voltage measurement and are electrically connected to the corresponding busbar segments 36, 46 of the busbar assemblies 20, 22. The lead frames 64 are therefore used for high-voltage contact within the high-voltage switch box 10. In addition, a partially recognizable pre-charging relay 68 was added.

Furthermore, the assembly 56 includes several connection interfaces 70, via which the fully assembled high-voltage switch box 10 can be connected to battery cells or a high-voltage electrical system of the motor vehicle in question. Not shown here are those related to 1 mentioned component carriers 14, 18, which serve to accommodate and/or support the various components of the high-voltage switch box 10.

In 12 the virtually fully assembled high-voltage switch box 10 is shown in a perspective view diagonally from above. That's why the in 11 Assembly 56 shown, among other things, added the control electronics 12, which is designed as a circuit board for the battery management controller. The component carriers 14, 18 serving as holding structures are again not shown here. An enclosure for the control electronics 12 is also not shown here. Finally, a residual cable set (not specified here) and possibly present is connected and respective electrical connections between the individual interfaces (not specified) of the lead frames 60, 64, the control electronics 12, the current and voltage sensor 42, a monitoring circuit (not specified here), usually as high Voltage Interlock Loop referred to, and the pyrotechnic separating element 50 produced.

It is essential when producing and in particular when assembling the high-voltage switch box 10 that the individual components of the high-voltage switch box 10 are assigned to respective pre-assembly assemblies. The components are then pre-assembled into the respective pre-assembly assemblies according to the assignment. In 1 Such a layout or such an assignment according to pre-assembly assemblies 12, 14, 16, 18, 20, 22, 26 is shown as an example.

After the pre-assembly assemblies have been pre-assembled, the actual assembly of the high-voltage switch box 10 takes place by placing the pre-assembled pre-assembly assemblies in the only possible assembly direction 30 (see 1 ) can be arranged one after the other and assembled step by step. The in 1 shown layer by layer structure and in connection with the 2 to 12 The components of the high-voltage switch box 10 mentioned are only to be understood as examples. What is essential is the modular and layered structure of the pre-assembly assemblies in one assembly direction 30. Regardless of its exact structure, the high-voltage switch box 10 has a standardized layout with regard to its individual components, which is designed with a view to optimized production. By bundling and prefabrication as well as preassembly of the individual preassembly assemblies and the later assembly and assembly in layers, mechanical and automated production or assembly is significantly promoted. The production and assembly of the high-voltage switch box 10 can thus take place in a standardized manufacturing sequence, for example along an automated assembly line.

REFERENCE SYMBOL LIST

10

High-voltage switch box

12

Control electronics

14

Component carrier

16

Low voltage contacting

18

Component carrier

20

Plus busbar assembly

22

Ground busbar assembly

24

Gapfiller gel

26

cooling plate

28

component

30

Mounting direction

32

Plastic on the cooling plate

34

Cooling plate connections

36

Busbar segments of the ground-busbar assembly

38

Plastic on the ground busbar assembly

40

recesses

42

Current and voltage sensor

44

High-voltage contactor

46

Busbar segments of the plus busbar system

48

Plastic on the plus busbar assembly

50

pyrotechnic separating element

52

Fuses

54

assembly

56

assembly

58

Temperature sensors

60

punched grid

62

Cables of the lead frame

64

punched grid

66

Cables of the lead frame

68

Precharge relay

70

Connection interfaces

Claims (8)

Method for producing a switch box, in particular a high-voltage switch box (10), for an electrically driven motor vehicle, comprising the steps: - Assigning individual components (28, 42, 44, 50, 52, 58, 68) of the switch box to respective pre-assembly brewing groups (12, 14, 16, 18, 20, 22, 26); - Pre-assembling the components (28, 42, 44, 50, 52, 58, 68) to the respective pre-assembly brewing groups (12, 14, 16, 18, 20, 22, 26) according to the assignment; - Assembling the switch box by assembling the pre-assembled pre-assembly groups (12, 14, 16, 18, 20, 22, 26) one after the other in a single assembly direction (30), one after the other, wherein at least one of the pre-assembly assemblies comprises a busbar assembly (20, 22), which is pre-assembled in an electrically conductive manner from individual busbar segments (36, 46) and equipped with at least one of the components (42, 44, 50, 52), in particular automatically equipped, and wherein the busbar segments (36, 46) are positioned in a proper arrangement relative to one another and are encased, in particular overmolded, with a thermally conductive and electrically insulating plastic (38, 48), and then connected to one another in an electrically conductive manner, wherein after the plastic (38, 48) has been covered, it is removed at predetermined locations and there the busbar segments (36, 46) come into contact with each other or the at least one component (42, 44, 50, 52) on one of the busbar segments (36, 46 ) is contacted. Procedure according to Claim 1 , characterized in that the assembly of the pre-assembled pre-assemblies (12, 14, 16, 18, 20, 22, 26) is carried out automatically. Method according to one of the preceding claims, characterized in that at least one of the pre-assembly assemblies is a cooling plate (26) through which a cooling medium can flow, which is pre-assembled and encased, in particular overmolded, with a thermally conductive and electrically insulating plastic (32). Method according to one of the preceding claims, characterized in that at least some of the components (28, 42, 44, 50, 52, 58, 68) are electrically connected to one another by means of at least one electrically conductive connection arrangement, which comprises a lead frame (60, 64). with several electrical conductors (62, 66). Procedure according to Claim 4 , characterized in that the electrical conductors (62, 66) are encased, in particular overmolded, with a thermally conductive and electrically insulating plastic. Method according to one of the preceding claims, characterized in that at least one of the pre-assembly assemblies is a component carrier (14, 18), in particular made of plastic, in and/or on which at least one of the components (28, 42, 44, 50, 52, 58, 68) is mechanically fixed and/or supported by at least one of the other pre-assembly assemblies (12, 16, 20, 22, 26). Method according to one of the preceding claims, characterized in that one of the pre-assembly assemblies comprises control electronics (12) which is connected to one or more components (28, 42, 44, 50, 52, 58, 68) of the other pre-assembly assemblies (14, 16, 18, 20, 22, 26) is connected in an electrically conductive manner. Method according to one of the preceding claims, characterized in that one of the pre-assembly assemblies (12, 14, 16, 18, 20, 22, 26) has at least one connection interface (70) for a battery or a high-voltage electrical system of the motor vehicle, which is connected to a the Busbar segments (36, 46) are electrically connected.

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