KR20200129264A - Device for protecting component and distributing power of electric vehicle - Google Patents

Abstract

A device for protecting parts and distributing power of an electric vehicle for converting an internal combustion engine vehicle into an electric vehicle includes: a housing member that physically protects electric vehicle parts and has an empty space therein; and a plurality of connectors which are electrically connected to the electric vehicle parts through the housing member. The device for protecting parts and distributing power of an electric vehicle according to an embodiment of the present invention efficiently distributes power to a high power device in an electric vehicle and protects parts of the high power device in the case of converting the internal combustion engine vehicle into the electric vehicle.

Description

Device for protecting component and distributing power of electric vehicle

Embodiments of the present invention are used to protect electric vehicle parts and power distribution devices that distribute power to a high power device in the electric vehicle and protect parts of the high power device when converting an internal combustion engine vehicle to an electric vehicle. About.

Electric vehicles (EVs) continue to grow in demand due to the gradual depletion of fossil fuels and the emission of carbon dioxide (CO2) from the exhaust gas of conventional internal combustion vehicles. Electric vehicles utilize electric drive motors operated by electric energy stored in batteries to provide power to the vehicle.

However, electric vehicles still have shortcomings in terms of technical aspects such as mileage and charging time, and in terms of cost such as high vehicle prices, and they have not yet been widely distributed to the public.

For this reason, research and development on technology that can convert a general internal combustion engine vehicle into an electric vehicle is steadily in progress. Since the old car is converted into an electric car, it is possible to enjoy the advantages of eco-friendly and economical electric cars as well as reducing vehicle replacement costs due to retirement, and clean and eco-friendly electric vehicles with internal combustion engines that require a large amount of fossil fuels. This is because switching to a car is expected to be effective in reducing carbon dioxide emissions.

On the other hand, the general method of converting an internal combustion engine vehicle into an electric vehicle is to use the 12v electric power source devices such as air conditioners, heaters, batteries, etc. of the internal combustion engine vehicle components as they are, and remove the remaining components. It is carried out by mounting electric vehicle parts such as battery packs. However, in the case of the conventional general conversion method, there is a disadvantage in that power distribution to the high power device and protection of components of the high power device are insufficient.

In order to solve the problems of the prior art as described above, in the present invention, when an internal combustion engine vehicle is converted into an electric vehicle, an electric vehicle that efficiently distributes power to a high power source device in the electric vehicle and protects the components of the high power source device. I would like to propose a component protection and power distribution device.

According to a preferred embodiment of the present invention to achieve the above object, as a protection and power distribution device for the electric vehicle parts for converting an internal combustion engine vehicle into an electric vehicle, physically protecting the electric vehicle parts, and A housing member having an empty space formed therein; And a plurality of connectors which pass through the housing member and are electrically connected to the electric vehicle component. A device for protecting and distributing power to an electric vehicle component is provided.

The electric vehicle component is a 12v electrical system component, and includes MCU (Motor Control Unit) related parts, PTC (Positive temperature coefficient) related parts, air conditioner related parts, LDC(Low voltage DC-DC converter) related parts, OBC(On- board charger) related parts, fast charging related parts, a positive busbar and a negative busbar, and the plurality of connectors include an MCU connector for the MCU related parts, the air conditioner related parts and the PTC related parts. An air conditioner/PTC connector, an LDC/OBC connector for the LDC-related parts and the OBC-related parts, a battery connector electrically connected to the positive and negative busbars, a quick charge connector for fast charging-related parts, and the electric vehicle parts. It may include a signal connector for transmitting an operation control signal.

The MCU-related component includes an MCU fuse, the air-conditioner-related component includes an air-conditioner relay and an air-conditioner fuse, the PTC-related component includes a PTC relay, a PTC fuse, and a PTC precharging register, and the LDC-related component is an LDC fuse. Including, the OBC-related component includes an OBC relay and an OBC fuse, and the fast charging-related component may include a fast charging relay and a fast charging fuse.

The positive busbar and the negative busbar may be electrically connected to the electric vehicle component and the plurality of connectors.

When the positive and negative power from the battery pack is supplied to the positive and negative busbars through the battery connector, the positive and negative power is supplied to a PDU (Power Distribution Unit), and the supplied positive and negative power The power of the electric vehicle is distributed to the electric vehicle part through the PDU, and the operation control signal is transmitted to the electric vehicle part through the signal connector to prevent overcurrent.

The positive busbar and the negative busbar may be electrically connected to the plurality of connectors, and the PTC relay, the PTC fuse, and the PTC precharging resistor may suppress an inrush voltage when initial power is applied.

According to the present invention, when an internal combustion engine vehicle is converted into an electric vehicle, there is an advantage of efficiently distributing power to a high power device in the electric vehicle and protecting parts of the high power device.

1 is a diagram schematically showing the configuration of an electric vehicle according to a method for converting an internal combustion engine vehicle into an electric vehicle according to an embodiment of the present invention.
2 is a flow chart illustrating a method for converting an internal combustion engine vehicle into an electric vehicle according to an embodiment of the present invention.
Figure 3 is a flow chart for explaining the electric vehicle vehicle design step of the method for converting an internal combustion engine vehicle to an electric vehicle according to an embodiment of the present invention.
4 is a schematic diagram of an electric vehicle component protection and power distribution device for converting an internal combustion engine vehicle into an electric vehicle according to an embodiment of the present invention.
Figure 5 is a schematic diagram of the electric vehicle component shown in Figure 4;

Hereinafter, specific embodiments of the present invention will be described in detail with reference to the drawings. However, the spirit of the present invention is not limited to the presented embodiments, and those skilled in the art who understand the spirit of the present invention can add, change, or delete other elements within the scope of the same idea. Other embodiments included within the scope of the inventive concept may be easily proposed, but it will be said that this is also included within the scope of the inventive concept.

In addition, components having the same function within the scope of the same idea shown in the drawings of each embodiment will be described with the same reference numerals.

1 is a diagram schematically showing the configuration of an electric vehicle according to a method for converting an internal combustion engine vehicle into an electric vehicle according to an embodiment of the present invention.

Referring to FIG. 1, an electric vehicle according to an embodiment of the present invention includes a vehicle control unit (VCU), a battery pack, an electric power train (EPT), a cooling system, and the like.

The VCU is a host controller that controls the overall operation of the electric vehicle, and performs integrated control by recognizing the operation status of the electric vehicle and the charging/replacement status of the battery pack. The VCU communicates with the MCU (Motor Control Unit) in a predetermined manner to control the torque and speed of the motor, which is the driving source of the electric vehicle, and the amount of generated torque.

The VCU communicates with the BMS (Battery Management System) in a predetermined manner to control the battery pack through the BMS and the PRA and control the power distribution to the electric motor through the PDU (Power Distribution Unit).

The VCU performs the function of extending the durability life by receiving the temperature of the battery pack from the BMS and maintaining the optimal temperature of the battery pack through the control of the electric vehicle cooling system.

In addition, the VCU can further control electronic components such as EVP, EWP, radiator fan, and backup lamp, and the EPT used to drive the vehicle is also controlled by the VCU. Therefore, the VCU controls the signals that control the electric vehicle. These signals are transmitted to control targets such as BMS, MCU, and cooling system through CAN network.

A battery pack is an energy storage device that supplies power to drive a motor of an electric vehicle. In general, a high-capacity battery pack that uses a large amount of electric energy at a high voltage of 360V is applied, but is not limited to capacity. Since high-capacity battery packs are required, battery cells are required from dozens to as many as thousands, and configurations vary slightly depending on the type of electric vehicle, but in order to safely and efficiently manage a large number of battery cells, it is in the form of a battery pack. It is installed on an electric vehicle. In other words, several battery cells are bundled to form a battery module, and several battery modules are bundled and installed in an electric vehicle in the form of a battery pack.

The battery pack additionally includes a battery management system (BMS), a low voltage DC-DC converter (LDC), a power relay assembly (PRA), and an on-board charger (OBC) for the operation of an electric vehicle.

BMS (Battery Management System) detects the overall state of battery cells such as voltage, current, temperature, etc. to estimate SOC (State of Charge), calculate real-time available outputs, control cell balancing, and relay ON/OFF. Perform. One BMS can manage the battery pack, and sub. It is also composed of the highest Master BMS with BMS.

BMS calculates the usable output of the battery pack according to SOC and temperature and transfers it to the VCU and PDU to enable optimal power distribution.

On the other hand, several battery cells connected in series/parallel inside the battery pack have a slight voltage difference for each battery cell due to the difference in internal resistance and deterioration rate, and the BMS detects the difference and uses the Cell Balancing function. By minimizing the voltage difference between the battery cells, the battery pack can operate stably.

In addition, BMS detects the temperature of the battery pack and transmits it to the VCU, thereby maintaining the optimum temperature of the battery pack through the control of the electric vehicle cooling system, thereby extending the durability life. Insulation can be secured through (Power Relay Assembly) control.

LDC (Low voltage DC-DC converter) is a robust low voltage DC-DC converter that steps down the high voltage DC voltage of an electric vehicle battery pack to a low voltage suitable for electronic equipment. LDC is a high voltage power supply system and a low voltage power supply system operating stably with each other. It has an isolated electrical structure to ensure safety.

OBC (On Board Charger) is a charger installed in the battery pack of an electric vehicle. It receives electric energy from an external energy source to charge the battery in the vehicle, and converts the supplied AC power to DC to charge the battery pack. can do.

OBC has DC high voltage output characteristics, includes a current control function for stably charging the battery, and can charge a constant current (CC) and a constant voltage (CV).

PRA (Power Relay Assembly) is composed of main relay, pre-charging relay, resistance, and current sensor to protect high voltage parts, and protects parts through vehicle Key On/Off sequence control, and battery failure, etc. Safety can be secured through relay off in case of emergency.

PRA secures electrical insulation between battery pack and connected parts, secures electrical stability in case of Key Off and emergency situations, prevents the occurrence of serious secondary accidents such as electric shock and fire caused by high voltage in case of an accident, and reduces the dark current of high voltage batteries. By blocking, it performs a function of preventing deep discharge of the battery pack.

EPT (Electric Power Train) includes a motor for driving an electric vehicle, a motor control unit (MCU) for controlling the motor, a power distribution unit (PDU) for power distribution, and a reduction gear for deceleration.

A motor is for driving an electric vehicle and is generally classified as an AC motor or a DC motor, and an AC motor is generally used. The AC motor is driven by converting DC power (DC) obtained from the battery pack into AC current (AC) through an inverter. Therefore, although precise control through the MCU is required, compared to DC motors, the size is smaller, lighter, and more efficient, and there is no brush, so that the number of rotations can be increased.

The MCU (Motor Control Unit) plays a role of controlling the motor. The MCU receives the motor control signal from the VCU and controls the torque and speed of the motor and the amount of generated torque. In addition, it receives a power distribution control signal from the PDU and performs power distribution control of the motor.

2 is a flow chart illustrating a method for converting an internal combustion engine vehicle into an electric vehicle according to an embodiment of the present invention, and FIG. 3 is a method for converting an internal combustion engine vehicle into an electric vehicle according to an embodiment of the present invention. This is a flow chart for explaining the stages of designing an electric vehicle vehicle.

Referring to Figure 2, the method for changing the internal combustion engine vehicle of the present invention to an electric vehicle, the step of removing the internal combustion engine components (S100), reverse designing step (S200), electric vehicle vehicle design step (S300), It includes a step (S400) of mounting and commissioning.

The step of removing the internal combustion engine component (S100) is a step of removing the internal combustion engine component from the engine mount of the internal combustion engine vehicle.

Specifically, removing the engine assembly device including at least one of an engine, a mission, an air compressor, a start motor, a timing belt, and an alternator, engine adjustment And removing the harness (Engine Control Harness) and the engine Electronic Control Unit (ECU). In addition, exhaust components and fuel tanks can be removed. The dual engine mount and engine control harness can optionally be reused at a later stage.

The reverse designing step (S200) is a step of reverse designing an electric vehicle component mounting space using a 3D scanner while the internal combustion engine components are removed.

Specifically, in the reverse designing step (S200), 3D data on the engine room, the lower part of the vehicle, and the trunk of the space where the internal combustion engine parts were removed using a 3D scanner, and the engine room, using the obtained 3D data, Perform 3D modeling of the lower part of the vehicle and the trunk, reverse design the vehicle based on 3D modeling, measure the weight of the front and rear of the electric vehicle before removing the internal combustion engine parts, and distribute the weight to minimize weight fluctuations even after remodeling Perform. In addition, it is possible to reduce the risk by additionally performing 3D modeling for the signal harness and high voltage cable.

The electric vehicle vehicle design step (S300) is a step of designing an electric vehicle vehicle and parts for assembling electric vehicle parts.

In more detail, referring to FIG. 3, the electric vehicle vehicle design step (S300) includes designing a mount and a cradle (S310), designing a power train (S320), It includes a step (S330) of designing the electrical wiring.

In the step of designing a mount and cradle (S310), 3D modeling is performed on the engine room, trunk and battery pack of the electric vehicle, and mounts and cradles for the engine room, trunk and battery pack ( Cradle).

In the step of designing a power train (S320), a power train is designed using a power distribution unit (PDU). Specifically, it is preferable to design such that the distance that can be driven through a single charge is 120 km, the maximum speed is 120 km/h, and the maximum mountain climbing is 25% or more, but the present invention is not limited thereto.

In addition, referring to FIG. 3, the step of designing an electrical wiring (S330) includes a step of designing a harness (S331), a step of designing an air conditioning system (S332), and a step of designing an EGS (S333). do.

In the step of designing a harness (S331), a harness is designed using a function of an engine control harness.

Specifically, it is designed so that the VCU can send control signals to EVP, EWP, Radiator FAN, Backup Lamp, EPT, etc. In addition to the existing CAN network, an EV CAN network that can send control signals to BMS, MCU, and PDU is additionally designed.

In the step of designing an air conditioning system (S332), an air compressor and a high voltage heater are connected with HVAC (Heating, Ventilation, Air Conditioning) installed in an existing vehicle, and a radiator is connected. Design the air conditioning system to be installed.

In the step of designing the EGS (S333), the gear shift located on the interior center console of the existing vehicle is removed and the EGS (Electric Gear Switch) is installed.

In the mounting and commissioning step (S400), an electric vehicle component is mounted and commissioned based on the design described above.

Specifically, the step of mounting and commissioning (S400) includes mounting the power train parts of the engine room in the vehicle, mounting the battery pack in the trunk, mounting the signal harness and high voltage cable, and then installing the VCU. Tuning the vehicle through a (Vehicle Control Unit), wherein the battery pack cable of the high-voltage cable utilizes a place where an existing exhaust part under the vehicle is mounted.

On the other hand, when converting an internal combustion engine vehicle to an electric vehicle, a 12v electric power source device such as an air conditioner and a heater battery of an internal combustion engine vehicle can be used as it is. In the case of the prior art, power distribution to the power source device and There is a disadvantage in that the protection of the components of the high power device is insufficient. Therefore, the present invention proposes an apparatus for solving the above-described disadvantages.

4 is a view showing a schematic configuration of an electric vehicle component protection and power distribution device for converting an internal combustion engine vehicle into an electric vehicle according to an embodiment of the present invention.

Referring to FIG. 4, the apparatus 500 for protecting and distributing electric power for electric vehicle components includes a housing member 510 and a plurality of connectors.

The housing member 510 physically protects the electric vehicle component, in particular, a 12v electric power source device that has not been removed and remains as shown in FIG. 5. In this case, an empty space is formed inside the housing member 510, and a 12v electric power source device is disposed in the empty space.

As an example of the present invention, as shown in FIG. 5, the power source device, which is an electric vehicle component, is a component related to a motor control unit (MCU), a component related to an air conditioner (A/S), and a component related to a positive temperature coefficient (PTC). , LDC (low voltage DC-DC converter) related parts, OBC (On-board charger) related parts, fast charging related parts, positive busbar and negative busbar.

Here, the MCU-related parts include the MCU fuse, the air conditioner-related parts include the air conditioner relay and the air conditioner fuse, the PTC-related parts include the PTC relay, the PTC fuse, the PTC pre-charging resistor, and the LDC The related parts may include an LDC fuse, the OBC related parts may include an OBC relay and an OBC fuse, and the fast charging related parts may include a fast charging relay and a fast charging fuse. Each relay and fuse is used to electrically protect each electric vehicle component.

In addition, the anode busbar and the cathode busbar are fixed to the plate, are electrically connected to the components of each electric vehicle, and are electrically connected to a plurality of connectors described below.

The plurality of connectors pass through the housing member 510 and are electrically connected to the electric vehicle component.

As an example of the present invention, a plurality of connectors are MCU connectors for MCU-related parts, air conditioner/PTC connectors for air conditioner-related parts and PTC-related parts, LDC/OBC connectors for LDC-related parts and OBC-related parts, and positive busbars. And a battery connector electrically connected to the negative busbar, a fast charging connector for fast charging-related parts, and a signal connector for transmitting an operation control signal to the electric vehicle component.

At this time, when the positive and negative power from the battery pack is supplied to the positive and negative busbars through the battery connector, the positive and negative power is supplied to the PDU (Power Distribution Unit), and the supplied positive and negative power May be distributed to the aforementioned electric vehicle parts through PDU. In addition, an operation control signal is transmitted to the electric vehicle component through the signal connector to prevent overcurrent. In addition, the PTC relay, the PTC fuse, and the PTC precharging resistor can suppress the inrush voltage when the initial power is applied.

In short, the electric vehicle component protection and power distribution device 500 of the present invention uses the 12V electric system of the existing internal combustion engine as it is, and protects the power source devices such as driving, air conditioner, heater, battery, etc. It was manufactured in a separate type to distribute and maintain. It can also protect people and vehicles against fast and slow charging.

In addition, when power is applied from the battery pack, power is applied through the MCU, and when overcurrent occurs, it is electrically protected by a fuse. It operates through a relay when the air conditioner and PTC are operated, and is electrically protected by a fuse when an overcurrent occurs. Power is supplied to each component through the positive busbar and connected to the MCU through the negative busbar. Relays and fuses are applied for quick charging operation to protect the vehicle and the driver electrically.

Through this, the operation of the high power electric device is easy, it is possible to protect against overcurrent, and in case of failure, it can be separated and repaired. It is easy to connect the fuse and relay of each component in one space.

In the above, the configuration and features of the present invention have been described based on the embodiments according to the present invention, but the present invention is not limited thereto, and various changes or modifications can be made within the spirit and scope of the present invention It will be apparent to those skilled in the art, and therefore, such changes or modifications are found to belong to the appended claims.

Claims (6)

In the electric vehicle component protection and power distribution device for converting an internal combustion engine vehicle into an electric vehicle,
A housing member that physically protects the electric vehicle component and has an empty space therein; And
And a plurality of connectors which are electrically connected to the electric vehicle component through the housing member. The method of claim 1,
The electric vehicle component is a 12v electrical system component, and includes MCU (Motor Control Unit) related parts, PTC (Positive temperature coefficient) related parts, air conditioner related parts, LDC(Low voltage DC-DC converter) related parts, OBC(On- board charger) related parts, fast charging related parts, positive busbar and negative busbar,
The plurality of connectors include an MCU connector for the MCU-related part, an air conditioner/PTC connector for the air conditioner-related part and the PTC-related part, an LDC/OBC connector for the LDC-related part and the OBC-related part, and a positive busbar. And a battery connector electrically connected to the negative busbar, a fast charging connector for fast charging-related parts, and a signal connector for transmitting an operation control signal to the electric vehicle part. . The method of claim 2,
The MCU-related component includes an MCU fuse, the air-conditioner-related component includes an air-conditioner relay and an air-conditioner fuse, the PTC-related component includes a PTC relay, a PTC fuse, and a PTC precharging register, and the LDC-related component is an LDC fuse. Including, wherein the OBC-related component includes an OBC relay and an OBC fuse, and the fast charging-related component includes a fast charging relay and a fast charging fuse. The method of claim 3,
The anode busbar and the cathode busbar are electrically connected to the electric vehicle component and the plurality of connectors. The method of claim 4,
When the positive and negative power from the battery pack is supplied to the positive and negative busbars through the battery connector, the positive and negative power is supplied to a PDU (Power Distribution Unit), and the supplied positive and negative power Power is distributed to the electric vehicle parts through the PDU,
Protection and power distribution device for electric vehicle parts, characterized in that the operation control signal is transmitted to the electric vehicle component through the signal connector to prevent overcurrent. The method of claim 5,
The positive busbar and the negative busbar are electrically connected to the plurality of connectors, and the PTC relay, the PTC fuse, and the PTC pre-charging resistor suppress an inrush voltage when initial power is applied. Components protection and power distribution devices.

Images