DE102010063126A1 - Device for charging high volt battery of motor vehicle e.g. electric vehicle, has monitoring device monitoring hazardous condition of device, and separating and/or discharge device transmitting control signal based on hazardous condition - Google Patents

Abstract

The device (2) has a discharge device (3) provided to discharge a capacitor (4), where the capacitor is placed in a region between a switchable separating device (1) and a potential separation device (5) of the device. A monitoring device (6) monitors hazardous condition (Zg) that is electric shock, of the device. The separating device and/or the discharge device transmits a control signal (Sig1, Sig2) based on the hazardous condition. The separating device comprises two-pole alternating current (AC) contactor for separating the device from a supply network. An independent claim is also included for a method for charging a high volt battery of a motor vehicle.

Description

Field of the invention

The invention relates to a charging device for motor vehicles with a vehicle high-voltage battery according to the preamble of the independent claim 1, as shown in DE 603 19 570 T2 known, and a corresponding charging method.

Technical background

In the development of modern motor vehicles, a reduction of the fuel consumption of the motor vehicle plays an increasingly important role. One measure to reduce the consumption of a motor vehicle is to combine the internal combustion engine with an electric drive in a hybrid vehicle. The electric drive in hybrid vehicles usually consists of an electric drive, which can also be operated as a generator, a high-voltage energy storage, from which the electric drive is supplied and an electronic control system.

There are three main types of hybrid vehicles. In a so-called mild hybrid, the electric drive mainly supports the combustion engine to increase performance and the braking energy can be partially recovered. As electromotive powers about 6-14 kW are given.

The so-called full hybrid vehicles with an electromotive power of more than 20 kW are able to drive purely by electric motor.

In the hybrid variants mentioned so far, the high-voltage energy storage devices are charged by means of energy recovery using the electric drive operated as a generator. Charging the high-voltage energy storage via an external power source is not provided.

To further reduce fuel consumption, the so-called plug-in hybrids offer the possibility of charging the high-voltage energy storage via an external energy source. In this case, the external energy source may be the public power grid, a solar and / or wind turbine or the like.

An alternative to vehicles with conventional internal combustion engines are electric vehicles. Unlike hybrid vehicles, electric vehicles do not have an internal combustion engine that can drive the motor vehicle. Therefore, in these vehicles charging the high-voltage energy storage via an external power source is necessary. The high-voltage energy storage is usually designed today as a vehicle high-voltage battery.

To charge the vehicle high-voltage battery of a hybrid or electric vehicle via, for example, a public power grid, a charging device is necessary.

The charging device connects an intermediate circuit of the vehicle, to which the high-voltage consumers of the vehicle and the high-voltage battery of the vehicle are connected, to the supply network via which the vehicle is to be charged.

Known charging devices for vehicle high-voltage batteries usually consist of a rectifier with line filter, a power factor correction circuit (PFC, Power Factor Correction) and a potential separation device. In electric and / or hybrid vehicles, the DC link is switched off and discharged when the vehicle is deactivated, disconnecting a plug of the high-voltage cabling of the vehicle or opening a lid of the charging device. The charging device and the components of the vehicle lying between the charging device and the supply network continue to be supplied with electrical energy via the supply network.

Summary of the invention

The present invention provides according to claim 1, a charging device for motor vehicles with a switchable separating device, which is adapted to all current-carrying conductors of a Charging cable, which connects the charging device to a supply network, to open and / or close, with a discharging device, which is designed to discharge a capacitor, wherein the capacitance is formed in the region between the separating device and a potential separation device of the charging device and with a monitoring device, which is designed to monitor the charging device to a dangerous condition, which causes the risk of electric shock, and to transmit to the separating device and / or the unloading device, depending on the dangerous condition, in each case a control signal.

Furthermore, the invention according to claim 9 provides a charging method, in particular for charging a vehicle high-voltage battery with a charging device according to the invention with the steps: monitoring the charging device to a dangerous condition, which causes the risk of electric shock, transmitting a control signal for opening to a disconnecting device, which is designed for this purpose to open and / or close all live conductors of the charging cable coupling the charging device to a supply network if the dangerous condition has been detected and to open the disconnecting device if a control signal for opening has been transmitted to the disconnecting device.

The realization of the present invention is that the opening of a lid of the charging device or other interference with the high-voltage cabling of a vehicle can cause the risk of electric shock to persons, but also electrical vehicle components, and disabling and discharging the DC bus of the vehicle is not sufficient protection represents an electric shock, since the charging device itself is still connected to the supply network and is not discharged.

The idea of the invention is now to monitor the charging device and the high-voltage wiring of the vehicle for the presence of a dangerous condition, which may cause an electric shock. If such a dangerous condition is detected, the charging device of the vehicle is disconnected from the electrical supply.

The electrical components of the charging device have a capacity which is electrically charged after connecting the charging device to a supply network. Even if the charging device is disconnected from the supply network, the electrical charge of this capacity is maintained. Therefore, in addition to disconnecting the charging device from the supply network, a discharger is activated which discharges the electrical charge of the capacitor. This is the opening and touching of components of the charger safely possible.

Advantageous embodiments and further developments will become apparent from the other dependent claims and from the description with reference to the figures of the drawing.

In one embodiment, the disconnect device includes at least one two-pole AC contactor for disconnecting the charging device from the utility grid. If an AC contactor is opened, no residual current flows through it. The use of an AC contactor therefore ensures that the charging device is completely disconnected from the supply network.

In a further embodiment, the separation device is provided as a component of an RCD circuit breaker in the plug of a charging cable which couples the charging device to a supply network and / or as a separate unit in the charging cable and / or as a disconnecting device coupled to the high-voltage input of the vehicle. If the separation device is provided at different points between the supply network and the capacity of the charging device, a flexible adaptation of the charging device to different conditions is possible. If, for example, a connector concept does not include an RCD circuit breaker in the plug of a charging cable, then one of the other two variants can be selected to accommodate the disconnecting device.

In a further embodiment, the discharge device is designed as a discharge resistor and / or the discharge device is formed as part of a rapid discharge of a vehicle intermediate circuit, wherein the capacity is discharged into the vehicle intermediate circuit, and / or the discharge device is formed as part of a power factor correction circuit of the charging device. Providing various ways to design the unloader increases the flexibility of the loader and simplifies integration of the loader into existing vehicle systems. The use of a discharge resistor represents a simple and inexpensive variant of a discharge device.

If a vehicle intermediate circuit is already present in a vehicle, which connects the charging device to the electronic components and the high-voltage battery of the vehicle, a rapid discharge present in this vehicle intermediate circuit can be used by the capacitance which is formed in the region between the disconnecting device and an electrical isolation device of the charging device is to unload. Another possibility is to use a power factor correction circuit to discharge the capacitance. For this purpose, the power factor correction circuit is controlled such that electrical losses occur in the power factor correction circuit and in the potential separation device, which discharge the capacitance. If the vehicle intermediate circuit of the vehicle is still integer, the energy of the capacity can be transmitted via the power factor correction circuit and the potential separation device in the vehicle intermediate circuit.

In a further embodiment, the dangerous state comprises opening a lid of the charging device, unplugging a high-voltage plug of a vehicle cabling. on the charging device, falls below a minimum insulation resistance and / or an accident. If all possible causes, which can cause the risk of electric shock, are monitored, a safe detection of a dangerous situation in the vehicle is possible.

In a further embodiment, the monitoring device is designed to be Disconnecting device in the presence of a dangerous condition to transmit a control signal to open. If the monitoring device responds to a dangerous condition by transmitting a control signal to the disconnecting device for opening, safe and timely disconnection of the charging device and the high-voltage cabling of the vehicle from the supply network is ensured.

In a further embodiment, the monitoring device is designed to transmit to the unloading device, in the presence of a dangerous condition, a control signal for discharging the capacity. If, in the presence of a dangerous condition, not only the disconnecting device is opened but also the capacity which is formed in the area between the disconnecting device and a potential separating device of the charging device is discharged, the risk of electric shock is eliminated as quickly as possible.

In another possible embodiment, the monitoring device is embodied as a discrete circuit, as a microcontroller, as an application-specific integrated circuit (ASIC) or as a combination of the named options. This allows a flexible adaptation of the monitoring device to different vehicle configurations.

Brief description of the drawings

The present invention is described below with reference to the schematic figures. the drawings specified embodiments explained in more detail. It shows:

1 a block diagram of an embodiment of a charging device according to the invention;

2 a flowchart of an embodiment of a charging method according to the invention for charging a vehicle high-voltage battery.

3 a schematic representation of a motor vehicle with a preferred embodiment of a charging device according to the invention.

4 a schematic representation of a motor vehicle with a further embodiment of a charging device according to the invention.

In all figures, identical or functionally identical elements and devices have been provided with the same reference numerals, unless stated otherwise.

Embodiments of the invention

1 shows a block diagram of an embodiment of a charging device according to the invention 2 for motor vehicles.

In 1 is with the reference numeral 1 a separator of a loading device 2 shown. The separator 1 is with a capacity 4 coupled with an unloading device 3 and an electrical isolation device 5 connected is. Further, a monitoring device 6 which monitors a dangerous condition Z _g and which is adapted to apply a signal Sig1 to the separating device 1 to send, such as a signal Sig2 to the unloading device 3 to send. Finally, there is a conductor LL with the separator 1 coupled. In the embodiment of the charging device according to the invention 2 monitors the monitoring device 6 the charger 2 and the high-voltage wiring of a vehicle 12 , as in 3 . 4 shown for the presence of a dangerous condition Z _g , which could cause an electric shock. Detects the monitoring device 6 Such a dangerous condition Z _g , it generates a control signal Sig1 to open, which it to the separator 1 transmitted. Then the separator separates 1 the charger 2 from a supply network 10 , as in 3 . 4 provided with the loading device 2 connected is. Furthermore, the monitoring device generates 6 a control signal Sig2 for discharging, which the monitoring device 6 to the unloading device 3 transmitted. The unloading device 3 then unloads the capacity 4 , With the unloading of the capacity 4 the risk of electric shock is eliminated. Maintenance or repair work on the loader 2 or the high-voltage wiring of the vehicle 12 can be carried out safely.

2 shows a flowchart of an embodiment of a charging method according to the invention 2 for charging a vehicle high-voltage battery 7 ,

In a first step S1, the loading device 2 monitored for a hazardous condition Z _g , which causes the risk of electric shock. In a second step S2, a control signal Sig1 is opened to the disconnecting device 1 if in the first step S1 the presence of the dangerous state Z _{g has been} detected. Finally, in a third step S3, the separating device opens 1 the connection between a supply network 10 and the charger 2 if in the second step S2, the signal Sig1 for opening to the separator 1 was transmitted.

In one embodiment of the charging device according to the invention 2 is the unloading device as part of a in 3 . 4 shown quick discharge 13 a vehicle intermediate circuit is formed. In such an embodiment, after opening the separator 1 the capacity 4 via the potential separation device 5 in the vehicle intermediate circuit 13 discharged. In this case, the power factor correction circuit operates 15 , as in 3 . 4 shown, the loader 2 further, as if the vehicle high-voltage battery 7 continue via the supply network 10 charged. This will in the capacity 4 existing electric charge via the potential separation device 5 in the vehicle intermediate circuit 13 transferred and discharged via the existing fast discharge.

In the vehicle intermediate circuit 13 is electrical energy with a voltage of up to 1000 V volts between the respective components connected to the vehicle DC link 13 connected, transmitted. In further embodiments, in the vehicle intermediate circuit 13 electrical energy with a voltage in a range of up to 5000 volts are transmitted. Preferably, the voltage corresponds to that in the vehicle intermediate circuit 13 electrical energy is transmitted, the rated voltage of the vehicle high-voltage battery 7 ,

In a further embodiment of the charging method according to the invention, the unloading device 3 for example, designed as a discharge resistor. Furthermore, the discharge resistor has a switch, with which the capacity 4 can be connected to the discharge resistor. In such an embodiment, after opening the separator 1 the unloading device 3 to the capacity 4 coupled to discharge them. The electric charge of the capacity 4 is then about the discharge resistance against the mass of the vehicle 12 dissipated.

3 shows a schematic representation of a motor vehicle 12 with an embodiment of the charging device according to the invention 2 ,

The loading device 2 consists of a separator 1 which with a capacity 4 connected, the capacity 4 with your unloading device 3 and a power factor correction circuit 15 connected is. The power factor correction circuit 15 Again, with a potential separation device 5 coupled. Furthermore, the in 1 illustrated loading device 2 a monitoring device 6 which is adapted to the separator 1 a signal Sig1 for opening and the unloading device 3 to transmit a signal Sig2 for discharging. The separator 1 is also with a high-voltage entrance 14 of the vehicle 12 coupled and the potential separation device 5 is with the DC link 13 coupled to the vehicle. The vehicle intermediate circuit 13 is via a second separator 9 with a high-voltage battery 7 of the vehicle 12 connected. Finally, the high-voltage entrance 14 of the vehicle 12 via a charging cable 11 , which has at least three conductors LL, with a charging plug 8th connected. The charging plug 8th is with a utility network 10 coupled. The operation of the charging device 2 corresponds in the in 3 illustrated embodiment of the operation of in 1 illustrated embodiment of the charging device according to the invention 2 , In the in 3 illustrated embodiment, the vehicle 12 over the charging cable 11 connected to a conventional AC outlet. Furthermore, the separation device 1 in the vehicle 12 with a high-voltage entrance 14 of the vehicle 12 coupled. This allows the use of a simple plug 8th on the charging cable 11 and a simple charging cable 11 because there are no further lines for signal transmission between the monitoring device 6 and one in the plug 8th existing separation device 1 must be provided. Furthermore, in 3 the monitoring device 6 with a second separator 9 coupled, which is designed to the high-voltage battery 7 from the DC link 13 of the vehicle 12 to separate. The monitoring device 6 monitored in the in 3 not only the charging device shown embodiment 2 itself and parts of the vehicle's high-voltage wiring 12 to a dangerous condition Z _g , which can cause an electric shock. Furthermore, the monitoring device monitors 6 in the in 3 illustrated embodiment, the intermediate circuit 13 of the vehicle 12 and the high-voltage battery 7 of the vehicle 12 as well as the wiring of the high-voltage battery 7 and the DC link 13 , Detects the monitoring device 6 the risk of electric shock in the vehicle intermediate circuit 13 or the high-voltage battery 7 of the vehicle 12 , so she opens the separator 9 , whereby the vehicle intermediate circuit 13 is disconnected from the electrical power supply. One in the vehicle intermediate circuit 13 existing rapid discharge discharges the in the vehicle DC link 13 existing capacity to eliminate the risk of electric shock.

4 shows a further embodiment of a charging device according to the invention 2 ,

In the 4 shown embodiment of a charging device according to the invention 2 is essentially the same as in 3 shown embodiment of a charging device according to the invention 2 , Unlike the in 3 shown embodiment of a charging device according to the invention 2 , points the in 4 illustrated embodiment of a charging device according to the invention 2 a separator 1 on which as a component of an RCD circuit breaker in the plug 8th of the charging cable 11 is executed. To the separating device 1 to be able to transmit a signal Sig1 is the monitoring device 6 via a signal line with the plug 8th of the charging cable 11 connected. The functioning of in 4 illustrated embodiment of a charging device according to the invention 2 corresponds to the operation of in 3 illustrated embodiment of a charging device according to the invention 2 , In the 4 illustrated embodiment of a charging device according to the invention 2 In addition, offers the advantage that the charging cable 11 from the supply network 10 is disconnected and thus tension-free as soon as the separator 1 is opened.

Although the present invention has been described above with reference to preferred embodiments, it is not limited thereto, but modifiable in a variety of ways.

In a further embodiment, the vehicle 12 over the charging cable 11 for charging the vehicle high-voltage battery 7 be connected to a three-phase socket. In a further embodiment, the vehicle 12 to be configured via the charging cable 11 with a special for charging vehicle high voltage batteries 7 provided high voltage power source 10 to be connected. Such a high voltage power source 10 For example, it can provide electrical energy at a voltage of up to 1000 volts.

A vehicle 12 For example, it can be charged on a home grid up to 16 A per phase. This corresponds to a conventional AC socket electrical charging of up to 3.7 kW and a three-phase socket electrical charging power of up to 11 kW.

In another possible embodiment, the vehicle 12 charged at a charging station for electric vehicles. At such a charging station, the vehicle 12 be charged with a current of up to 32 A per phase. This corresponds to charging the vehicle 12 with a single-phase charging cable 11 a charging power of up to 7.4 kW and when charging the vehicle 12 with a three-phase charging cable 11 a charging power of up to 22 kW. On special versions of such a charging station, a vehicle 12 be charged quickly with a DC voltage of 600 V with a charging current of up to 400 A with a charging power of up to 240 kW.

In other possible embodiments, the vehicle 12 Charging stations with higher voltages of up to 2000 V are charged.

The separator 1 In the respective embodiment, it has the number of circuit breakers which is necessary for a safe separation between the vehicle 12 and the supply network 10 or another source of energy 10 to guarantee. Is the vehicle 12 connected to a conventional AC outlet, the separator has 1 two disconnectors on. Is the vehicle on the other hand 12 connected to a three-phase socket, the separator has 1 three disconnectors on.

In some embodiments, the vehicle may 12 via conventional plug-in connectors for AC power sockets or for three-phase sockets with the charging cable 11 be coupled. In other possible embodiments, the vehicle 12 specifically for use in vehicles 12 developed connector with the charging cable 11 get connected.

In a further embodiment, the capacity is unloaded 4 by a suitable control of the power factor correction circuit 15 , This will be the power factor correction circuit 15 so driven that in the power factor correction circuit 15 and the potential separation device 5 electrical losses occur, which are suitable, the capacity 4 to unload. If the capacity is unloaded 4 by appropriately driving the power factor correction circuit 15 , is not another dedicated unloading device 3 necessary and a simple charging device 2 can be provided. In another embodiment, the power factor correction circuit discharges 15 and the potential separation device, the corresponding energy storage by a transfer of energy in the vehicle intermediate circuit.

In another possible embodiment, the function of the monitoring device 6 in one already in the vehicle 12 existing control device integrated as a program code component. This enables effective use of existing resources and easy integration of the monitoring device into existing vehicle systems.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 60319570 T2 [0001]

Claims (11)

Charging device for motor vehicles: with a switchable disconnecting device ( 1 ), which is designed to all current-carrying conductors (LL) of a charging cable ( 11 ), which the charging device ( 2 ) with a supply network ( 10 ) couples to open and / or close; with a discharge device ( 3 ), which is designed to have a capacity ( 4 ), the capacity ( 4 ) in the area between the separator ( 1 ) and a potential separation device ( 5 ) of the charging device ( 2 ) is trained; with a monitoring device ( 6 ), which is adapted to the loading device ( 2 ) to monitor a dangerous condition (Z _g ), which causes the risk of electric shock, and the separation device ( 1 ) and / or the unloading device ( 3 ) in each case a control signal (Sig1, Sig2) in response to the hazardous condition (Z _g ). Loading device according to claim 1, characterized in that the separating device ( 1 ) at least one at least two-pole AC contactor for disconnecting the charging device ( 2 ) from the supply network. Loading device according to one of claims 1 or 2, characterized in that the separating device ( 1 ) as a component of an RCD circuit breaker in the plug ( 8th ) of a charging cable ( 11 ), which the charging device ( 2 ) with a supply network ( 10 ), and / or as a separate unit in the charging cable ( 11 ) and / or as to the high-voltage entrance ( 14 ) of the vehicle ( 12 ) coupled separation device ( 1 ), is provided. Loading device according to one of the preceding claims, characterized in that the unloading device ( 3 ) is formed as a discharge resistor; and / or that the unloading device ( 3 ) as part of a rapid discharge of a vehicle intermediate circuit ( 13 ), the capacity ( 4 ) in the vehicle intermediate circuit ( 13 ) is unloaded; and / or that the unloading device ( 3 ) as part of a power factor correction circuit ( 15 ) of the charging device ( 4 ) is trained. Loading device according to one of the preceding claims, characterized in that the dangerous state (Z _g ) is an opening of a lid of the loading device ( 2 ), unplugging a high-voltage connector of a vehicle wiring to the charging device ( 2 ), falls below a minimum insulation resistance and / or has an accident. Loading device according to one of the preceding claims, characterized in that the monitoring device ( 6 ) is adapted to the separation device ( 1 ) in the presence of a hazardous condition (Z _g ) to transmit a control signal (Sig1) for opening. Loading device according to claim 6, characterized in that the monitoring device ( 6 ) is adapted to the unloading device ( 3 ) in the presence of a hazardous condition (Z _g ), a control signal (Sig2) for discharging the capacity ( 4 ). Loading device according to one of the preceding claims, characterized in that the monitoring device ( 6 ) is designed as a discrete circuit, as a microcontroller, as an application-specific integrated circuit (ASIC) or as a combination of said options. A charging method, in particular for charging a vehicle high-voltage battery with a charging device according to one of claims 1 to 8, with the steps: monitoring (S1) of the charging device ( 2 ) to a dangerous condition (Z _g ), which causes the risk of electric shock, transmitting (S2) a control signal (Sig1) for opening to a separating device ( 1 ), which is designed to all current-carrying conductors (LL) of the charging cable ( 11 ), which the charging device ( 2 ) with a supply network ( 10 ) couples to open and / or close if the hazardous condition (Z _g ) has been detected; Opening (S3) of the separating device ( 1 ), if the separator ( 1 ) a control signal (Sig1) has been transmitted for opening. A charging method according to claim 9, further comprising the steps of: transmitting a control signal (Sig2) for discharging to an unloading device (Sig2) 3 ), which is designed to have a capacity ( 4 ), if the dangerous condition (Z _g ) in the charging device ( 2 ) and / or the motor vehicle ( 12 ) was detected. Unloading the capacity ( 4 ) by the unloading device ( 3 ) if a control signal (Sig2) has been transmitted to the unloading device for unloading. Loading method according to one of claims 9 and 10, characterized in that the monitoring of the loading device ( 2 ) monitoring the charging device ( 2 ) on opening a lid of the charging device ( 2 ) and / or unplugging a high-voltage connector of a vehicle cabling on the charging device ( 2 ). and / or has an accident.

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