DE102010041362B4 - Charging device for an electric vehicle with an electrical connector attached to the electric vehicle with fasteners - Google Patents

Abstract

Charging device (1,2,3,4,5) for an electric vehicle (6) with an electrical connector (1) for establishing an electrical connection to a charging station (7), characterized in that the electrical connector (1) is optionally in at least two operating positions (A, B) can be brought, in particular into a first operating position (A), in which the electrical connector (1) can be fixed to the electric vehicle with the aid of fastening means (5) in such a way that a charging cable (8) is mechanically and electrically conductive to the Electrical connector (1) can be connected; and - into a second operating position (B), in which the electrical connector (1) can be moved relative to the electric vehicle and mechanically and electrically connected to a charging station (7), the electrical connector (1) having switching means (11) which effect that the electrical connector (1) is optionally compatible with a first mating connector (81) or a second mating connector (71).

Description

The invention relates to a charging device for an electric vehicle with an electrical connector that can preferably be attached to the electric vehicle with fasteners and has the features of the preamble of the main claim.

An electric vehicle is an electric vehicle that is powered by an electric motor. The electric motor draws its power from an energy storage device, e.g. B. battery or battery that is housed in the electric vehicle. The battery must be recharged after being discharged. A charging device in the sense of the present invention is used to charge the battery. The charging device can be part of the electric vehicle or part of a charging station. If the battery of an electric vehicle is to be charged, the charging device of a charging station is mechanically and electrically connected to the charging device of an electric vehicle. The battery can then be charged using electrical current supplied by the charging station.

From the publication DE 10 2009 052 366 A1 shows a charging device of an electric vehicle, which includes, on the one hand, a socket or a charging socket and, on the other hand, a charging plug that is connected to an electric cable. The charging plug and charging socket are located behind one or two covers on the body of the electric vehicle. To charge, the charging plug can be pulled out after opening the corresponding lid and plugged into a socket. Conversely, an external charging plug connected to an electric cable can be plugged into the electric vehicle's socket to charge the electric vehicle. From this publication DE 10 2009 052 366 A1 There are various options for suitably accommodating the electric cable in the electric vehicle. A drum with a pull-in is suggested on which the electrical cable can be wound. Spring forces can be provided in order to be able to pull an electrical cable into an interior space. An additional servo motor can optionally be provided. The charging plug of the motor vehicle is plugged into the socket of the motor vehicle when not charging in order to fix the charging plug when not in use.

From the publication DE 10 2009 057 659 A1 a motor vehicle for passenger transport is known, comprising an energy storage and a coupling unit, which is connected to the energy storage via an energy transmission unit, the energy transmission unit being arranged in such a way that the coupling unit arranged on the energy transmission unit can be guided outside the motor vehicle with a predeterminable length.

From the publication DE 201 01 983 U1 a supply connection device is known, which is characterized by a drum that can be permanently installed within the vehicle for rolling up a supply line, such as an electrical connection cable or a water hose with at least one outlet that can be connected to the vehicle's on-board electrical system, which supply line is rolled up on the drum and from it against the The force of a spring element can be unrolled and carries at its free end a connection means for connecting the supply line to a stationary supply station, a vehicle-side outlet through which the supply line is led out of the vehicle and in which the connection means of the supply line is accommodated when the supply line is rolled up on the drum .

From the republished publication EN 10 2011 006 633 A1 a motor vehicle with an electric drive is known. It can be a motor vehicle with a hybrid drive. The object of the invention is to provide a motor vehicle of the type mentioned above which can be supplied with fuel for the internal combustion engine and, by means of a charging station, with electricity for charging the battery of the electric motor. To solve the problem, the motor vehicle comprises a recess which is adjacent to the body of the motor vehicle. Inside the recess there is a charging socket or a charging plug which is connected to a battery. The battery serves to provide electricity for the electric motor with which the motor vehicle can be driven. In addition, inside the recess there is one end of a fuel filler neck which is connected to a tank so that fuel can be filled into the tank.

From the publication DE 694 09 414 T2 an electric vehicle with a built-in charging device is known.

From the subsequently published publication DE 10 2009 016 895 A1 a charging connection device for an at least partially electrically driven motor vehicle is known, comprising a connection body which can be attached to an opening of the motor vehicle and forms a connection space, further comprising an electrical connection device for electrically connecting a battery of the motor vehicle to an electrical supply source provided outside the motor vehicle Charging the accumulator, characterized in that the electrical connection device has a charging cable, which ches can be connected to the accumulator and has an electrical plug-in device for connecting to the electrical supply source, that the electrical connection device has a cable winding device with a rotatably mounted cable reel, the cable reel being biased into a reel-up position in which the charging cable is rolled up on the cable reel and the plug-in device is arranged within the connection space formed by the connection body and is accessible from the outside, so that the plug-in device for connecting to the external electrical supply can be pulled out of the connection body together with the charging cable, the charging cable being unrolled from it against the pretension of the cable reel becomes.

It is therefore known to connect a current-producing charging station to an electrical connector on an electric vehicle via a separate charging cable - similar to an electrical extension cable. It is also known to accommodate the electric cable on a spring-loaded drum in the electric vehicle, similar to a vacuum cleaner, so that the plug can simply be pulled out and led to the charging station.

It is intended to design the electrical connectors on the electric vehicle and at the charging station so differently that a connection using a charging cable is possible, but several charging cables cannot be plugged in one after the other. This limitation to short charging cable lengths is necessary for safety reasons due to the high currents. However, this also limits the flexibility in using the electrical connection because couplings do not fit together.

Against this background, it is the object of the invention to provide a device and a method for easy charging of an electric vehicle.

To solve the problem, a charging device with the features of claim 1 is proposed. Advantageous refinements are the subject of the subclaims.

The charging device according to the invention according to claim 1 can be part of an electric vehicle or part of a charging station that can supply the electricity for charging an electric vehicle. The charging station can supply direct current and/or alternating current, for example in the form of three-phase current, for charging the battery of an electric vehicle. The charging device includes a plurality of electrical contacts (connectors) for connecting to electrical contacts of a corresponding charging device. If the charging device according to the claim is mechanically and electrically connected as part of a charging station to a corresponding charging device of an electric vehicle, the battery of the electric vehicle can then be charged. For example, the charging device comprises, on the one hand, electrical contacts that are used for charging with direct current, and on the other hand, electrical contacts that are used for charging with alternating current. In addition, the charging device may include electrical contacts that serve control purposes or other secondary purposes, such as supplying power to an electric drive or an electric locking device. An electrical and mechanical connection here means that the electrical connectors are operationally safe, i.e. secured against accidentally falling out, and the charging current can flow.

The charging device for an electric vehicle comprises an electrical connector, preferably attached to the electric vehicle with fastening means. This corresponds to the state of the art with a fixed or removable charging socket. This serves to establish an electrical connection with a charging station located away from the electric vehicle. In order to charge, the electrical connector is necessarily connected electrically to the electric vehicle via an electrical cable, specifically usually to a charging controller or directly to the accumulator or battery. The electrical cable can be a fixed wiring inside the electric vehicle that is connected to the fixed electrical connector. However, it can also be a removable electrical cable that can be pulled out of the electric vehicle together with the electrical connector.

According to the invention it is now provided that the charging device is designed in such a way that the electrical connector can be brought into at least two operating positions. The two operating positions are in particular two different plug depths or contact depths of, for example, 34 mm and 44 mm. It can therefore be used flexibly, depending on local conditions, both with an external charging cable and without an external charging cable, e.g. B. be connected electrically and mechanically at a gas station or with a charging station. The external charging cable then basically also has the two operating positions at its two ends, i.e. in particular two different plug depths or contact depths of, for example, 34 mm and 44 mm. To put it colloquially, the idea is that a plug that hangs on a self-retracting electric cable of the electric vehicle can also serve as a fixed charging socket and can preferably adopt different mating plug compatibility modes. Then there are very few At least two different connection options are available for charging with electricity. The external electrical cable

In the first connection option mentioned above with the external electrical cable, the electrical connector is brought into a first operating position in one embodiment, in which the electrical connector is fixed to the electric vehicle in such a way that the external charging cable can be connected to the electrical connector in a mechanical and electrically conductive manner. In the second connection option mentioned above without using an external electrical cable, the electrical connector is brought into a second operating position in which the electrical connector can be moved relative to the electric vehicle and mechanically and electrically connected to a charging station (7).

In one embodiment, there is always a charging cable available that can be easily pulled out of an electric vehicle and which the driver cannot lose or have to look for. This can be used to bridge the usual - usually short, typical gas station distances - from the electric vehicle to the charging station. The electrical connector is released from the attachment of the electric vehicle and pulled out, pulling the electrical cable behind it. It is plugged into the charging station, which is referred to here as the second operating position. For example, if an electrical connector of the charging station is designed for an insertion depth of 44 mm, then the insertion depth of the vehicle-side electrical connector in the second operating position is 44 mm.

Alternatively, the same vehicle-side electrical connector can be used as a connection socket permanently mounted on the electric vehicle. For this purpose, in one embodiment, the electrical connector is fixed to the electric vehicle via releasable fasteners, so that an external charging cable can be plugged into the electrical connector without having to hold the vehicle-side electrical connector by hand. In this first operating position it serves as a permanently installed charging socket. This enables the use of an external, suitable charging cable, the use of which requires the electric vehicle to be in the first operating position. The use of an external electrical cable can e.g. B. may be necessary in order to be able to bridge longer distances to the charging station due to unfavorable structural conditions. The external electrical cable can therefore be designed with a higher cross section, for example. This also enables automatic connection using robot arms that expose the vehicle-side electrical connector and connect it to an external charging cable. The invention therefore allows both operating modes with less space, especially in the visually visible area of the body, compared to the solution DE 10 2009 052 366 A1 .

The at least two operating positions can also be used to be able to charge the battery of an electric vehicle with the help of another electric vehicle in order to be able to provide breakdown assistance.

Preferably, an opening is provided in a surface of the electric vehicle, in which the electrical connector is positioned in the first operating position (A). When connecting the charging cable, the electrical connector is easily accessible. It is preferably arranged inconspicuously in a recessed position. This applies in particular if a detachable, preferably hinged cover is provided on the opening, behind which the electrical connector is hidden in the first operating position and thus protected from visibility and environmental influences. A tank cap flap is preferably provided as a cover, which can preferably cover further connections, in particular electrical plugs or sockets or filler necks for fuel. The usual fuel filler flap therefore covers several connections and the usual appearance of motor vehicles is not changed.

If preferably the electrical cable can be pulled out, in particular against a spring force and/or the electrical cable can be wound on an electrical cable drum, for example, the electrical cable is always safe and well guided and stored. Kinks are avoided and the usual comfort of the vacuum cleaner cable retraction is guaranteed. If preferably the electrical cable can be pulled out through the opening, the tank flap in particular can cover this opening. The electrical cable is on the one hand easily accessible and on the other hand protected.

• Erfindungsgemäß weist der erfindungsgemäße Elektrokonnektor Umschaltmittel auf, die bewirken, dass dieser wahlweise mit einem ersten Gegenkonnektor, z. B. dem fahrzeugseitigen Ende eines externen Ladekabels, oder einem zweiten Gegenkonnektor, z. B. der Buchse an der Ladestation kompatibel ist. Kompatibilität bedeutet hier, dass zwischen den Komponenten eine mechanische und elektrisch leitende Verbindung hergestellt werden kann. Der Elektrokonnektor kann also „umschalten“, um Inkompatibilitäten zu vermeiden.

The following design takes into account the flexibility restrictions that arise when the electrical connectors on the electric vehicle and at the charging station are designed differently in order to prevent several similar charging cables from being plugged in one after the other:

• According to the invention, the electrical connector according to the invention has switching means which cause it to be optionally connected to a first mating connector, e.g. B. the vehicle-side end of an external charging cable, or a second mating connector, e.g. B. the socket on the charging station is compatible. Compatibility here means that a mechanical and electrically conductive connection can be established between the components. The electric konnektor can therefore “toggle” to avoid incompatibilities.

Preferably, the electrical connector is optionally only compatible with the first mating connector or the second mating connector, but not with both at the same time. This prevents incorrect operation.

Suitable switching means here are, in particular, movable locks or electrical contacts that can be moved between two positions. These can be done manually, i.e. H. can be consciously activated by an action by the user regardless of the position of the electrical connector. This means that the electrical connector can advantageously be loosened and pulled out of the electric vehicle with the electrical cable and adapted to the available mating connector.

Preferably, the switching means are designed such that the electrical connector is compatible with the first mating connector when the electrical connector is in the first operating position and/or the electrical connector is compatible with the second mating connector when the electrical connector is in the second operating position. The electrical connector is therefore always compatible with the mating connector located in the corresponding operating position. This switching can be done manually or automatically.

However, the switching means are preferably designed to be automatically switchable and switch as soon as the electrical connector changes its position. This can e.g. B. as soon as the electrical connector leaves a first position or is connected to or separated from the first or second mating connector. Automatic switching here means that no additional conscious action on the part of the operator is necessary, but rather the switching takes place automatically, e.g. B. when loosening or inserting the electrical connector from or into the fasteners. The switching can be done by electric motor or by spring force. It is easiest if, for example, B. when inserted into vehicle-side fasteners, the switching takes place, for example, against a spring tension and when released from the fastening means, for example, a released spring force ensures a new switching.

The switching means are preferably designed in such a way that different insertion depths can be achieved in the connection between the electrical connector and the mating connectors, which provides additional security against incorrect operation. For this purpose, the switching means can preferably have a plurality of pins or sockets which are movable in the axial direction, i.e. can be shortened or extended, in order to selectively effect an electrically conductive connection with corresponding mating sockets or mating pins of the first mating connector or the second mating connector.

In one embodiment, the second counter-connector is a power connection of the charging station, i.e. a power-supplying socket.

In keeping with this, the first mating connector forms one end of an external charging cable. The other end of the external charging cable is compatible with the second mating connector. This is one way to increase the flexibility described above.

It is expressly emphasized that the invention can also be used in the opposite arrangement, i.e. H. is claimed as part of a charging station with a pull-out electrical connector. In the corresponding parts of the description and the corresponding claims, only the terms “vehicle” and “charging station” would have to be interchanged, where these serve as position information for the electrical connectors and electrical cables.

Further advantages result from the following description and the attached figures. Likewise, the above-mentioned and further detailed features can be used according to the invention individually or in any combination with one another. The exemplary embodiments mentioned are not to be understood as exhaustive and are of an exemplary nature.

1 shows a detail of an electric vehicle 6 with a charging device according to the invention, which can be electrically connected to a charging station 7. The electric vehicle 6 includes a battery 4, which in the present case is connected to an electrical connector 1 on the vehicle side via a charge controller 3 and an electrical cable 2 accommodated in the vehicle 6. The electrical connector 1 is located in the area of the surface of the body and is mounted in an opening 61 provided therein. The opening 61 is closed with a hinged tank cap flap 62 as long as no charging cable is connected or the electrical connector 1 is not pulled out.

The electrical connector 1 according to the invention is connected via a suitable fastening means 5, e.g. B. a correspondingly shaped holder, magnetic contacts, clamping contacts, actuator with movable latch or the like on the vehicle, here within the opening 61 and below the flap 62, held in such a way that a corresponding mating contact piece 81 of an external charging cable 8 can be connected to it. The electrical connector 1 is anchored in the area of the fuel filler flap in a similar way to a connection socket on conventional electric vehicles that is permanently connected to the vehicle, so that the driver can easily plug in the mating connector 81 of the charging cable 8 without having to hold the electrical connector 1 with the other hand. For example, it can be connected with just one hand. The electrical connector 1 is therefore in the first operating position A and in this, for example, has a contact depth or plug depth of 34 mm. The other end 82 of the charging cable 8 is inserted into a corresponding mating connector 71 of the charging station 7 so that the charging process can take place. To connect the end 82 to the mating connector 71, for example, a plug depth or a contact depth of 44 mm may be required. The charging cable 8 can alternatively also be firmly connected to the charging station 7 at the end 82 so that a plug connection would be available.

2 shows another connection option for the same vehicle 1 . However, the separate, external charging cable 8 is not used here. Rather, the electrical connector 1 is released from the fastening means 5 and pulled out of the vehicle 6 together with its electrical cable 2, which in the present case is done through the opening 61 in which the electrical connector was previously positioned.

The electrical connector 1 is then in the second operating position B, in which the electrical connector has, for example, a contact depth or plug depth of 44 mm. In the second operating position B, the electrical connector 1 can therefore be directly connected mechanically and electrically to the electrical connector of the charging station 7. After the charging process, the electrical connector 1 is returned to the fastening means 5, with the electrical cable 2, for example, through the above-mentioned. Measures or, for example, due to electrically driven rollers resting on the electric cable 2 on the vehicle side, withdraws automatically. The fastening means 5 can, for example, have releasable snap-in connections and springs, so that, for example, when the electrical connector is inserted, a spring is tensioned and the fastening means 5 snap into place. To release the electrical connector, the snap-in connection must be released, with the stored spring force moving the electrical connector towards the driver, which makes it easier to pull out the electrical connector.

In the 1 and 2 the two counter-connectors 81, 71 have different connection dimensions, with switching means 11 being provided in the electrical connector 1, which ensure that the electrical connector assumes a different configuration depending on the operating position A or B and is optionally compatible with the first or second counter-connector 81, 71.

3 explains by way of example the function of such a switching means 11 using electrical connectors, namely pins 91, 92 and sockets 93. However, additional switching means are usually also necessary. In the 3 Sockets 93 shown under A) and B) on the right are long sockets, e.g. B. designed with an insertion depth of 44mm and are part of a charging socket on a charging station. These long charging sockets 93 require matching long pins 91 for connection, also with an insertion depth of 44mm. In order to create an electrical connection, one end of an electrical cable connected to the vehicle can now be brought to the long socket 93 of the charging station with the pin 91 (dashed arrow) and plugged into it.

Under b), on the other hand, the case is shown in which an extension cable 94 with mutually incompatible sockets 94A and pins 94A is used. The socket 94A has a smaller insertion depth, e.g. B. 34mm, compared to the large socket 93 on the charging station. This therefore requires a matching short pin 92 on the vehicle side, which also has a plug depth of 34mm, for example. To connect, the short socket 94a of the charging cable 94 must now be brought to the matching short pin 92 of the vehicle-side electrical connector. This results in the need for the vehicle-side electrical connector to have a pin, which can either be designed as a long pin 91 or a short pin 92. This can be done, for example, by a conductive pin 95 that is movably mounted in the axial direction 3C) will be realized. The electrically conductive pin 95 is arranged in a housing 111 so that it can be displaced in the axial direction by the length L, springs or other restoring elements can be provided which can force the pin 95 into one or the other position in the absence of other forces. Alternatively or additionally, the movement of the pin 95 between the two positions can be done electromagnetically, electromotively or electrically with the aid of a shape memory alloy. It is important that the pin 95 is protected by suitable measures, e.g. B. sliding contacts or a cable connection can be connected to a power line; The current fed in on the right side must therefore be able to leave the switching device 11 at another point. Preferably, a cylindrical section 96 can be provided, which has a larger cross section than the pin 95, thus over the resulting larger contact area a lower electrical contact resistance can be generated to the housing 111.

Reference symbol list

1

Electrical connector

11

switching means

111

Housing of the switching means

2

Electric cable

3

Charge controller

4

battery

5

Fasteners

6

Electric vehicle

61

opening

62

Fuel cap flap

7

Charging station

71

second counter-connector

8th

Charging cable

81

first counter-connector

82

other end of the charging cable

A

first operating position

b

second operating position

91

long pen

92

short pen

93

long socket

94

Charging cable

94A

short socket on the charging cable

94B

long pin on the charging cable

95

movable pen

96

cylindrical section

Claims (15)

Charging device (1,2,3,4,5) for an electric vehicle (6) with an electrical connector (1) for establishing an electrical connection to a charging station (7), characterized in that the electrical connector (1) is optionally in at least two operating positions (A, B) can be brought, in particular - into a first operating position (A), in which the electrical connector (1) can be fixed to the electric vehicle with the aid of fastening means (5) in such a way that a charging cable (8) is mechanically and electrically conductive to the Electrical connector (1) can be connected; and - into a second operating position (B), in which the electrical connector (1) can be moved relative to the electric vehicle and mechanically and electrically connected to a charging station (7), the electrical connector (1) having switching means (11) which effect that the electrical connector (1) is optionally compatible with a first mating connector (81) or a second mating connector (71). charging device Claim 1 , characterized in that the electrical connector has a different insertion depth or plug depth in the first operating position than in the second operating position, the insertion depth or plug depth being preferably 34 mm in the first position and preferably 44 mm in the second position. charging device Claim 1 or 2 , wherein an opening (61) is provided in a surface of the electric vehicle, in which the electrical connector is positioned in the first operating position (A), preferably in a recessed position and in particular a detachable, preferably hinged cover (62) on the opening ( 61) is provided, behind which the electrical connector (1) is hidden in the first operating position (A). Charging device according to one of the preceding claims, wherein a tank cap flap is provided as a cover for the electrical connector (1), which can preferably also cover further connections, in particular electrical plugs or sockets or filler necks for fuels. Charging device according to one of the preceding claims, wherein an electric cable (2) connected to the electrical connector can be pulled out, in particular against a spring force and/or on an electric cable drum and/or through the opening (61), in an interior, in particular in an interior of the Electric vehicle electric vehicle is stored. Charging device according to one of the preceding claims, wherein the switching means (11) are movable locks or electrical contacts that can be moved between two positions. Charging device according to one of the preceding claims, wherein if the electrical connector is compatible with the first mating connector (81), it is not compatible with the second mating connector (71) and / or if the electrical connector is compatible with the second mating connector, it is not compatible with the first Counter connector is compatible. Charging device according to one of the preceding claims, wherein the switching means (11) is such are designed so that the electrical connector is compatible with the first mating connector (81) when the electrical connector is in the first operating position (A) and / or the electrical connector is compatible with the second mating connector (71) when the electrical connector is in the second operating position (A) Are. Charging device according to one of the preceding claims, wherein the switching means (11) are designed such that different insertion depths can be achieved in the connection between the electrical connector (1) and the mating connectors (81, 71), preferably an insertion depth of 34 mm and an insertion depth of 44 mm. Charging device according to one of the preceding claims, wherein the switching means are activated automatically as soon as the electrical connector leaves the first or second operating position (A, B) or is connected to or disconnected from the first or second mating connector (81, 71). Charging device according to one of the preceding claims, wherein the second mating connector (71) is a power connection of a charging station (7). Charging device according to one of the preceding claims, wherein the first mating connector (81) forms one end of a charging cable (8) and the other end (82) of the charging cable (8) is compatible with the second mating connector (71). Charging device according to one of the preceding claims, wherein the switching means (11) have a plurality of pins or sockets which are movable in the axial direction in order to selectively effect an electrically conductive connection with corresponding counter sockets or counter pins of the first counter connector (81) or the second counter connector (71). Charging device according to one of the preceding claims, wherein the electrical connector is electrically connected to the electric vehicle via an electrical cable (2). Set with a charging device according to one of the preceding claims and an additional external charging cable, the charging cable in particular having two different plug and/or contact depths of, for example, 34 mm and 44 mm.

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