DE102006047039A1 - Contact connection for motor vehicle`s electrical drive motor, has safety device with sensor system for detecting closed contact position of contact parts, where system has sensor and magnet that are galvanically separated from each other - Google Patents

Abstract

The connection has two contact parts (4A, 4B) for detachable electric connection of two partial sections of a power cable (2). A closed contact unit is arranged in housings (6A, 6B), and a safety device activates the power cable with the closed contact unit. The safety device has a sensor system for detecting a closed contact position of the contact parts. The sensor system has a reed sensor (10A) and permanent magnet (10B), which are galvanically separated from each other.

Description

The The invention relates to a contact connection, in particular for releasable electrical Connection of an electric drive motor of a motor vehicle.

at such a customary designed as a plug connection high current or high voltage contact connection Special security precautions are required to ensure safe disconnection and connecting the plug contact connection to ensure. In particular, must be sure that when separating or when joining the Contact connection that is de-energized and de-energized for as long as if the individual contact elements of the contact connection still or already in a contact position.

A Such contact compound is particularly used in so-called Hybrid drive motors in motor vehicles, in which to drive the Motor vehicle in addition to a conventional internal combustion engine additionally another electric motor is used. Due to the high electrical power of the respective electric motor, for example, 50 kW and more must the contact connection for transmission be trained by high performance.

Of the Invention is based on the object of specifying a releasable contact connection, in the permanent safe separation or connection is possible.

The Task is according to the invention solved by a contact connection, in particular plug-in contact connection with the features of claim 1. The contact connection points afterwards for releasable Connection of two sections a power train two in particular on the type of plugs trained contact parts, each one arranged in a housing Include contact element. The contact compound further comprises a Safety device for activation of the power train exclusively at closed contact elements. The safety device has this a sensor system with two sensor elements for detecting a closed Contact position of the contact parts, wherein the two sensor elements permanently galvanically isolated.

Under Power train is understood here as an electrical line, the for the transmission of high electrical power of several kW, especially for electrical Supply of an electric drive motor is suitable.

The Contact connection is therefore through the sensor system and the safety device virtually monitored, so that only at complete closed position of the two contact parts a current flow over the Contact connection is allowed. Of particular importance for the security device Here is that the two sensor elements are not galvanic and thus need conductive contact, to generate a control or sensor signal. The sensor elements are therefore galvanically isolated in every position and thus permanently from each other. This is a permanently high operational and reliability especially in the adverse environmental conditions during use guaranteed in a motor vehicle. In particular, there is no risk of corrosion, for example due to moisture ingress, no risk of breakage as well also no risk of manipulation, for example by bridging, to disable the safety device.

The Safety device usually includes a switch for enabling the power train, wherein the Switch with the aid of a control signal of the sensor system switchable is. Under activation here is the Bestromen the power line or at least the application of an operating voltage understood. As soon as So with the help of the sensor system, the closed contact position is detected by the sensor system, a control signal to the switch delivered over this control signal switched either directly or indirectly becomes. The switch is in particular a high-power semiconductor switch. This is preferably directly over the control signal switched. Alternatively, the switch formed as an electromechanical relay, which indirectly when needed via the Control signal is switched.

According to one expedient development is a non-contact sensor system intended. The two sensor elements therefore act in the manner of a Proximity switch together, so that the control signal is issued only when the two contact parts are in a certain relative position to each other. The non-contact Working sensor system is particularly robust against contamination or similar. Due to the environmental influences, therefore, the reliability unaffected.

Around permanently safe functioning guarantee is the sensor system according to a preferred Embodiment designed as a magnetic sensor system comprising a magnetic sensor and a magnet, in particular permanent magnets, as sensor elements includes. This allows for cost-effective, reliable and commonly available components resorted become.

In particular, a so-called reed sensor is used as the magnetic sensor. At a Reed sensor or reed contact are two contact tongues usually sealed under vacuum or inert gas in a glass flask. The two contact tongues form a contact spring and a magnet armature and can be contacted with the help of a magnet, such as permanent magnets with each other and switch it. Such reed contacts or sensors are particularly favorable, extremely robust and reliable, so that they are particularly suitable for the securing device of the contact connection. As an alternative to the reed sensor, a Hall sensor or a so-called MR sensor can also be used.

Prefers the two sensor elements are designed in the manner of a fork contact, associated with or attached to the first contact part, wherein the second contact part a triggering element in particular in the form a Metalli rule pin or plate is assigned, which insertable between the two sensor elements of the fork contact is. The sensor elements of the fork contact are in this case in particular a magnetic sensor and a permanent magnet and by the insertion the metal pin of the trigger element is the acting on the magnetic sensor, in particular reed contact Enriched magnetic field sufficiently, so that the reed contact switches and thus the control signal for activation the safety device is delivered.

alternative to the embodiment of the sensor system as a magnetic sensor system this is in preferred variants as a capacitive, inductive, optical or pressure-sensitive sensor system formed. The individual sensor elements are electrodes (capacitive sensor system), Coils (inductive sensor system), light sources and light sensors, in particular on a semiconductor basis (optical sensor system) and pressure-sensitive Switch or button, which by a second sensor element acting stop on the second contact part to be actuated. As pressure-sensitive Switch is for example an optical switch or a Provided piezoelectric element.

Around to achieve a particularly effective protection against environmental influences, is according to a convenient one Design of at least one of the sensor elements and are preferably encapsulated both sensor elements. Under encapsulated here is the especially hermetic seal, so that the sensor element splashproof and in particular is sealed gas-tight. For this purpose, the Sensor elements preferably poured or molded. you will be as an encapsulated unit either in a corresponding inclusion in casing used or alternatively they are used in the production of the usual injection-molded housing with encapsulated or poured.

Around the functionality to ensure the sensor system is further provided that at least one, preferably both Sensor elements to the contact elements of the contact parts electrically are shielded. This is around the respective sensor element around provided an electrical shield. Age native for this exists also the possibility the electrical shield around the contact elements of the respective To arrange contact part.

Around one possible simple and compact design to achieve the sensor elements in an expedient embodiment integral components of Contact parts, that is, they are attached directly to the contact parts or in one piece, for example by molding or the like connected to these.

Prefers are the sensor elements together with the contact elements inside the case arranged so that they are protected by the housing.

In an alternative advantageous embodiment, the sensor elements on the outside of the housing arranged, which preferably has a shield. hereby is a good shielding of the sensor elements over the Contact elements achieved, so that no interference by electromagnetic intolerance are to be expected.

alternative to the arrangement on or in the contact parts is in a preferred Design provided that at least one of the sensor elements a component housing is assigned, in which one of the two contact parts integrated is. In this embodiment Therefore, the contact part of the contact connection is not loose end posted on a cable of the power train but is rather integral part of a component, for example a control unit with power electronics.

embodiments The invention will be explained in more detail below with reference to the drawings. It show each in schematic and simplified representations:

1A -C a contact connection with two contact parts in a closed contact position, an intermediate position and a fully open position in each case in greatly simplified side representations,

2A -C representations according to 1A -C a second embodiment in which the Sen Sorelemente are arranged on the outside of the contact parts,

3A -C representations according to 1A -C a third embodiment in which the sensor elements are arranged in the manner of a fork contact and

4 a side view of a fourth embodiment in which one of the contact parts is integrated in a component housing.

In the figures are equivalent parts each with the same reference numerals Mistake.

The electrical contact connection shown in the figures is in each case designed as a plug-in contact connection and serves for the detachable connection of two line parts of a power train 2 together. The contact connection is therefore designed as a detachable plug connection. It is preferably used for the electrical connection of an electric drive motor of a motor vehicle or other components of a motor vehicle (battery, air conditioning, etc.). In particular, in motor vehicles with a hybrid drive, so a drive either with electric motor or engine, the contact connection for electrical supply of the electric motor or for dissipation of electrical energy, when the electric motor is operated in overrun mode (braking operation) as a generator. Usually, the left half of the picture shown in the figures is connected to a motor vehicle battery, generally voltage source, whereas the right side is connected to the electric motor / generator. Due to the high power consumption or output of the electric drive is the power train 2 designed for very high electrical power. In particular special is the power train 2 and thus the contact connection for the transmission of power up to 600 A and a voltage also designed by several hundred volts.

The two parts of the power train 2 be with the help of two trained as plug parts contact parts 4A , B interconnected. The two contact parts 4A , B comprise a housing 6A , B and contact elements 8A , B. The contact element of the contact part shown on the left half of the picture 4A is here as a socket 8A and corresponding thereto is the other contact element as a contact pin 8B educated.

The contact connection furthermore has a sensor system which has two sensor elements 10A , B has. In the illustrated embodiments, the sensor element 10A as a reed sensor and reed contact and the sensor element 10B designed as a permanent magnet. From the reed sensor 10A leads a two-wire control line 12 to a switch shown here only dashed lines 14 , The ends of the control line 12 are each with a respective contact tongue of the reed contact 10A connected. The reed sensor 10A is designed in the manner of a switch. Comes the reed sensor 10A in sufficient proximity to the magnet 10B , Thus, an electrical contact connection between the two contact tongues is formed by the magnetic force. With closed contact tongues is on the control line 12 a control voltage of, for example, 5 V to a maximum of about 24 V, which is fed by a voltage source, such as the motor vehicle battery. About this control voltage is the switch 14 , For example, a semiconductor power switch or an electromechanical relay, connected. The desk 14 serves for electrical isolation or connection of the power train 2 , With open switch 14 is the power train 2 in the area of the contact parts 4A , B current and voltage free, so with open switch 14 a loosening or connecting the plug contact connection is easily and safely possible.

The sensor system comprises the two sensor elements 10A , B and is part of a safety device, which also has the control line 12 as well as the switch 14 includes.

The operation of the safety device with the sensor system is in all variants as follows: In the in the 1A . 2A and 3A shown fully closed contact position are the two contact parts 4A , B completely into each other until mechanical stops, so that the contact pin 8B in a contact set position in the socket 8A is plugged in. In this closed contact position are the contacts of the reed sensor 10A in contact with each other, so over the control line 12 to a control input of the switch 14 the control voltage is applied.

In the in the 1B . 2 B and 3B Although shown intermediate position are the two contact elements 8A , B still in contact connection, however, have the two sensor elements 10A , B so far apart that the reeds of the reed sensor 10A are separated and via the control line 12 at the switch no control voltage is applied. Due to the lack of control voltage, the switch opens 14 so the power train 2 is galvanically isolated. Already in the in the 1B . 2 B and 3B shown intermediate position is therefore the power train 2 voltage and current free. The contact connection can therefore be completely solved safely, so that the two contact parts 4A , B are completely separated, as in the 1C . 2C . 3C and 4 is shown.

About the sensor system, therefore, a kind of proximity switch is realized, which only at a predetermined relative position between the two contact parts 4A , B a control signal to the switch 14 so that it is closed and the power train 2 is energized. The opening / closing of the switch 14 This happens already / only in the intermediate position in which the contact elements 8A , B are already / already contacted. This measure ensures that the two contact elements 8A , B energized contact with each other or separated from each other.

By the use in particular of a non-contact, preferably Magnetic sensor system is the functioning of the sensor system and so that the entire safety device is very robust and resistant against possible contamination in the contact connection area.

In the embodiment according to the 1A to C are the two sensor elements 10A , B in each case directly in the respective contact parts 4A , B integrated. They are especially within the housing 6A , B encapsulated, for example, cast. In order not to influence the electrical functionality is additionally preferably provided that the sensor elements 10A , B to the contact elements 8A B are electrically shielded out, so that act on the sensor system due to the high currents or high voltages no interference signals.

In the embodiment according to the 2A to C are the two sensor elements 10A , B respectively on the outside of the respective housing 6A , B arranged. In this case, in particular the effect is exploited that the housing 6A , B itself already acts in the manner of a shield.

Finally, in the embodiment according to the 3A to C the sensor system formed in the manner of a fork contact. Here are both sensor elements 10A , B in the one contact part 4A arranged. They are stationarily positioned relative to each other, with a free space formed between them. In this space is when merging the two contact parts 4A , B a metal pin or plate 16 inserted as a trigger element. By inserting the metal pin 16 this will be on the reed sensor 10A acting and permanent magnet 10B resulting magnetic field decreases, so that the two contact tongues of the reed sensor 10A (in one embodiment as an opener) due to the insufficient magnetic force in their contact position and a control signal via the control line 12 to the switch 14 is created. In this embodiment, therefore, the sensor system additionally includes the metal pin acting as a triggering element 16 , In this respect, the metal pin forms 16 also a kind of passive sensor element.

Finally, in the embodiment according to 4 the contact part 4A directly into a component housing 18 integrated. In this case, this is a sensor element, namely the reed sensor 10A , no longer an immediate component of the contact part 4A but is on or in the component housing 18 in the immediate vicinity of the contact part 4A arranged. Inside the component housing 18 For example, a power electronics is provided with a circuit arrangement on a printed circuit board, on which, among other things, the switch 14 is integrated. The power electronics in particular also assumes control functions that are necessary and necessary for the electric drive. In particular, the charging of a motor vehicle battery in overrun mode during braking is controlled by this electronics, for example.

2

power train

4A, B

contact part

6A, B

casing

8A

receptacle

8B

pin

10A

Reed sensor

10B

permanent magnet

12

control line

14

switch

16

metal pin

18

component housing

Claims (12)

Contact connection, in particular for the electrical connection of an electric drive motor of a motor vehicle, with two contact parts ( 4A , B) for the detachable electrical connection of two sections of a power train ( 2 ), each one in a housing ( 6A , B) arranged contact element ( 8A , B), and with a safety device for activating the power train ( 2 ) only with closed contact elements, wherein the securing device is a sensor system for detecting a closed contact position of the Kontakteile ( 4A , B) and the sensor system comprises two sensor elements ( 10A , B), which are permanently galvanically isolated. Contact connection according to claim 1, wherein a non-contact working sensor system is provided. Contact connection according to claim 1 or 2, wherein the sensor system as a magnetic sensor system with a magnetic sensor ( 10A ) and a magnet ( 10B ) is designed as sensor elements. Contact connection according to Claim 3, in which, as a magnetic sensor ( 10A ) a reed sensor is provided. Contact connection according to Claim 3 or 4, in which both the magnetic sensor ( 10A ) as well as the magnet ( 10B ) the first contact part ( 4A ) and spaced from each other are fixedly positioned, wherein the second contact part ( 4B ) a trigger element ( 16 ), which is between the magnetic sensor ( 10A ) and the magnet ( 10B ) in a connection of the contact parts ( 4A , B) is insertable. Contact connection according to claim 1 or 2, in which optionally a capacitive, inductive, optical or pressure-sensitive Sensor system is provided. Contact connection according to one of the preceding claims, in which at least one of the sensor elements ( 10A , B) is encapsulated. Contact connection according to one of the preceding claims, in which at least one of the sensor elements ( 10A , B) to the contact elements ( 8A , B) is shielded. Contact connection according to one of the preceding claims, in which the sensor elements ( 10A , B) integral components of the contact parts ( 4A , B). Contact connection according to one of the preceding claims, in which the sensor elements ( 10A , B) together with the contact elements ( 8A , B) in the housing ( 6A , B) are arranged. Contact connection according to one of Claims 1 to 9, in which the sensor elements ( 10A , B) on an outside of the housing ( 6A , B) the contact parts ( 4A , B) are arranged. Contact connection according to one of claims 1 to 9, wherein at least one of the contact parts ( 8A ) in a component housing ( 18 ) and at least one of the sensor elements ( 10A ) on the component housing ( 18 ) is arranged.