Powertrain with high-power distribution module and high-current ring terminal connection for the same

Patent metadata

Field	Value
Publication number	US-10005366-B1
Application number	US-201615367834-A
Country	US
Kind code	B1
Filing date	Dec 2, 2016
Priority date	Dec 2, 2016
Publication date	Jun 26, 2018
Grant date	Jun 26, 2018

Abstract

A system includes a rechargeable energy storage system (RESS) having an enclosure, battery cells, contactors, a first pair of high-voltage interlock (HVIL) ports, and female blind-mate electrical sockets selectively connected to the battery cells via the contactors. The battery cells and contactors are within the RESS enclosure. The system includes a high-power distribution module (HPDM) having another enclosure, male blind-mate electrical pins, a second pair of HVIL ports engagable with the first pair, ring-terminal connections connected to the blind-mate electrical pins and connectable to high-current components, and HV280 electrical connectors electrically connected to one or more of the male blind-mate electrical pins. The male blind-mate electrical pins insert directly into and engage with the female blind-mate electrical sockets of the RESS enclosure. A vehicle includes the system, a transmission, and an electric machine.

First claim

What is claimed is:

1. A system comprising:
a rechargeable energy storage system (RESS) having an RESS enclosure, a plurality of battery cells, a plurality of contactors, a first pair of high-voltage interlock (HVIL) ports, and a plurality of female blind-mate electrical sockets selectively connected to the battery cells via operation of a corresponding one of the contactors, wherein the battery cells and the contactors are contained within the RESS enclosure;
an RESS heater module contained within the RESS enclosure and electrically connected to the plurality of battery cells; and
a high-power distribution module (HPDM) having an HPDM enclosure, a plurality of male blind-mate electrical pins, a second pair of HVIL ports engagable with the first pair of HVIL ports, a plurality of ring-terminal connections electrically connected to the blind-mate electrical pins and connectable to a plurality of high-current components including a power inverter module and a DC charging module, and a plurality of HV280 electrical connectors connectable to a respective one of a plurality of high-voltage components and electrically connected to one or more of the male blind-mate electrical pins within the HPDM enclosure, wherein the high-current components require a higher electrical current than each of the high-voltage components;
wherein the plurality of male blind-mate electrical pins of the HPDM enclosure are configured to insert directly into and engage with the plurality of female blind-mate electrical sockets of the RESS enclosure to thereby electrically connect the HPDM enclosure directly to the RESS enclosure.

2. The system of claim 1 , further comprising: at least one of an auxiliary power module, a cabin heater control module, an onboard charging module, and an air conditioning control module connected to a respective pair of the blind-mate electrical pins via a corresponding one of the HV280 electrical connectors.

3. The system of claim 2 , including each of the auxiliary power module, the cabin heater control module, the onboard charging module, and the air conditioning control module.

4. The system of claim 3 , further comprising:
a bundle of electrical cables, each cable being connected to a respective one of the auxiliary power module, the cabin heater control module, the onboard charging module, and the air conditioning control module; and
an elbow fitting configured to route the cables to the blind-mate electrical pins.

5. The system of claim 1 , further comprising: a water seal configured to prevent ingress of water and debris into the HPDM enclosure.

6. The system of claim 1 , wherein the RESS enclosure includes multiple support rails, the battery cells are arranged between the support rails on a first side of the support rails, and the HPDM enclosure is connected to a second side of the support rails with at least one of the support rails disposed between the RESS enclosure and the HPDM enclosure.

7. The system of claim 1 , further comprising: a transmission having an input member and an electric machine that is electrically connected to the battery cells, and that is operable for generating and delivering a motor torque to the input member.

8. The system of claim 1 , wherein the high-current component draws at least 300 amps.

9. A vehicle comprising:
a transmission having an input member;
a rechargeable energy storage system (RESS) having an RESS enclosure, a plurality of battery cells, an RESS heater module contained within the RESS enclosure and electrically connected to the plurality of battery cells, a plurality of contactors, a first pair of high-voltage interlock (HVIL) ports, and a plurality of female blind-mate electrical sockets selectively connected to the battery cells via operation of a corresponding one of the contactors, wherein the battery cells and the contactors are also contained within the RESS enclosure;
an electric machine having a motor shaft that is coupled to the input member, and that is electrically connected to the battery cells, and that is operable for generating and delivering a motor torque to the input member;
a plurality of high-current components each drawing at least 50 amps and including a power inverter module and a DC charging module; and
a high-power distribution module (HPDM) having an HPDM enclosure, a plurality of male blind-mate electrical pins, a second pair of HVIL ports engagable with the first pair of HVIL ports, a plurality of ring-terminal connections electrically connected to the blind-mate electrical pins and connectable to the plurality of high-current components, and a plurality of HV280 electrical connectors connectable to a respective one of a plurality of high-voltage components and electrically connected to one or more of the male blind-mate electrical pins within the HPDM, wherein the high-current components require a higher electrical current than each respective one of the plurality of high-voltage components;
wherein the plurality of male blind-mate electrical pins of the HPDM enclosure are configured to insert directly into and engage with the plurality of female blind-mate electrical sockets of the RESS enclosure to thereby electrically connect the HPDM enclosure directly to the RESS enclosure.

10. The vehicle of claim 9 , wherein each of the high-current components draws at least 300 amps.

11. The vehicle of claim 9 , further comprising at least one of an auxiliary power module, a cabin heater control module, an onboard charging module, and an air conditioning control module connected to a respective pair of the blind-mate electrical pins via a corresponding one of the HV280 electrical connectors.

12. The vehicle of claim 11 , including each of the auxiliary power module, the cabin heater control module, the onboard charging module, and the air conditioning control module.

13. The vehicle of claim 12 , further comprising: a bundle of electrical cables, each cable being connected to a respective one of the auxiliary power module, the cabin heater control module, the onboard charging module, and the air conditioning control module, and an elbow fitting configured to route the cables to the blind-mate electrical pins.

14. The vehicle of claim 9 , further comprising: a water seal disposed configured to prevent ingress of water and debris into the HPDM enclosure.

15. The vehicle of claim 9 , wherein the RESS enclosure includes multiple support rails, the battery cells are arranged between the support rails on a first side of the support rails, and the HPDM enclosure is connected to a second side of the support rails with at least one of the support rails disposed between the RESS enclosure and the HPDM enclosure.

Assignees

• Gm Global Tech Operations Llc

Inventors

• Wang Konking
• Conlon Brendan M
• Schwab Leo F
• Bilinski Alexander M
• Heien Stephen G

Classifications

• B60L58/27

  by heating · CPC title

• B60L50/16

  with provision for separate direct mechanical propulsion · CPC title

• B60L50/66

  Arrangements of batteries · CPC title

• H02J7/751

  concerning the insertion or the connection of the batteries · CPC title

• H02J7/50 Primary

  acting upon multiple batteries simultaneously or sequentially · CPC title