DE102015002704A1 - Charging cable, method of charging a vehicle-mounted battery, and method of assembling a power-supply control device - Google Patents

Abstract

The invention relates to a charging cable for charging a vehicle-mounted battery, comprising a first connector 10 for connection to an electric power supply, a second connector 20 for connection to a vehicle-side connector, a cable for connecting the first and second connectors 10, 20, wherein the cable is provided with a power supply controller PCSA for controlling a power supply from the electric power supply to the vehicle, the power supply controller PCSA comprising: a housing 30 for housing a power supply board 100 and a control unit Regulator plate 200, wherein the power supply board 100 includes: first terminal fittings 150 for connection to associated terminal fittings 180 provided at one end of wires leading to the first connector 10, and second terminal fittings 160 for Ver a power supply line 190 for connecting the first and second terminal fittings 150, 160, wherein the power supply line 190 is formed as a conductive path of the power supply circuit board 100.

Description

The present invention relates to a charging cable for charging a battery installed in a vehicle such as a hybrid vehicle or an electric vehicle. Further, the invention relates to a power supply control device for a charging cable, a method of charging a vehicle-mounted battery, and a method of assembling or manufacturing a power supply control device of a charging cable.

Batteries installed in electric or hybrid vehicles must be charged from an external power source, such as a commercial AC electric power source. For this purpose, the vehicle must be connected to the external power source, such as a power source of 100 V, 110 V, 220 V or 250 V, via a charging cable. Such a charging cable includes at least two power lines, a grounding line and a signal line or a data bus for connecting a power supply control device provided in the middle of the charging cable with a controller or a charging device installed in the vehicle is. The power supply control device performs the function of connecting or disconnecting the power lines to and from the vehicle depending on a state of charge of the battery installed in the vehicle, the function of disconnecting the power lines in the event of excessive current due to a defect, and Display of information for a user.

Accordingly, the power supply control device provided inside the charging cable includes switches or relays for enabling switching between a connected state and a disconnected state of the power lines, and a controller or a control panel and display devices such as LEDs. Furthermore, a fuse circuit must be incorporated in the power supply control device to cause disconnection in the event of a failure, such as excessive current flowing through the power lines.

Conventionally, the control and protection devices incorporated within the power supply control device must be connected to power and signal wires or bus bars and the like. Therefore, numerous assembly steps are required to manufacture the power supply controller. Furthermore, the power supply control device has an excessive size so that all the components can be accommodated inside of their case.

Accordingly, it is an object of the invention to provide a charging cable for charging a battery installed in a vehicle such as an electric vehicle or a hybrid vehicle, which includes a power supply control device, as well as a power supply control device and in the provision of a method of charging a battery and a method of assembling the power supply control device, wherein the power supply control device has a small size and can be assembled by a minimum of assembling steps. Furthermore, all safety regulations must be met.

The object is achieved by the features of the independent claims. Particular embodiments of the invention are the subject of the dependent claims.

According to a first aspect, there is provided a charging cable for charging a vehicle-mounted battery, comprising: a first connector for connection to an electric power supply, a second connector for connection to an associated vehicle-side connector, and a cable for connecting the first and second connectors; wherein the cable is provided with a power supply control device for controlling a power supply from the electric power supply to the vehicle, the power supply control device comprising:
a housing for housing a power supply board and a control panel,
wherein the power supply board includes: first terminal fittings for connection to associated terminal fittings provided at one end of wires leading to the first connector, and second terminal fittings for connection to associated terminal fittings provided at one end of wires leading to the second connector; and a power supply line for connecting the first and second terminal fittings, wherein the power supply line is formed as at least one conductive path of the power supply circuit board.

Thus, the first terminal fittings are electrically connected to the first connector via a first portion of the charging cable, and the second terminal fittings are electrically connected to the first connector second connector connected via a second section of the charging cable. Preferably, the first portion of the charging cable has a shorter length than its second portion, so that the power supply control device is provided close to the electric power supply line. However, the invention is not limited to such a configuration. The first section may also be longer or the same length as the second section of the charging cable. Alternatively, the power supply control device may include the first connector so that the power supply control device is connected to an infrastructure socket. In this way, the charging cable has only the second section, but not the first section.

In particular, the power supply control device has a two-layer structure including the power supply board and the control pipe plate. Preferably, no further printed circuit boards are provided so that the power supply control device comprises only the power supply printed circuit board and the control or rectifier plate. No further wires, bus bars, and the like, more or more layers of conductive paths are required. The power supply controller simply connects the first and second terminal fittings through the integrated power supply path or path integrated with or forming part of the power supply board.

In particular, the circuit board mechanically supports and connects electronic components using conductive traces, pads, and other features etched from copper layers provided on a dielectric laminate (eg, laminated, deposited by electrostatic deposition, or the like) this electrically. At least two of the conductive tracks are intended to supply power from the first to the second terminal fittings. In addition, one of the conductive traces constitutes the required ground terminal. The printed circuit board is generally made of a dielectric material comprising a copper layer. The substrate is subjected to drilling, chemical etching and / or lamination to provide the circuit board comprising the required conductive paths. Electronic or electrical components may be attached to the circuit board by inserting one or more respective pins or such leads into holes drilled in the printed circuit board (PCB) and soldering the pins of the component to the tracks or paths that are on the PCB are provided to make electrical contact therewith.

Accordingly, in particular, the power supply control device is an integrated device including only the power supply board and the control board and only needs to be connected to the respective associated terminal fittings provided at the end of the wires of the first and second connectors. In particular, no further wires or bus bars or the like are provided within the power supply control device to connect respective ones of the first terminal fittings and each of the second terminal fittings. Therefore, the power supply controller has a small size and can be easily assembled.

Preferably, the first terminal fittings are at least partially surrounded by a current sensor for controlling a current conducted to the power supply board.

Since the current sensor is at least partially surrounded by the first terminal fittings, there is no need for an additional wire or electrical path to detect the current through the current sensor. In particular, it is not necessary to arrange a dedicated wire around the current sensor. Accordingly, the number of components can be reduced. The current sensor may be a Hall effect sensor or an AC suitable transformer. The Hall sensor detects a voltage difference across the first terminal fittings across the electrical current in the first terminal fittings and a magnetic field perpendicular to the current. The Hall coefficient is defined as the ratio of the induced electric field to the product of the current density and the applied magnetic field. It is a property of the material of which the first terminal fittings are made, since its value depends on the type, number and characteristics of the carriers forming the current. The current in the Hall effect is formed by the movement of many small charge carriers, such as electrons, holes, ions or all three. However, a transformer may also be used as a current sensor that produces a varying magnetic flux in the core and a varying magnetic field.

Preferably, the control or regulator platen is selected from a plurality of control platters having a different layout. Accordingly, the same components in the first and second connectors, the cable, the housing and the power supply board may be used on various control board plates to provide various power line charging cables. For example, a "basic design" may include a display, such as LEDs, to indicate functions and / or loading issues, while a "comfort design" may additionally include multiple buttons to select between different charging modes or to control the charging period; to regulate and the like more. A "premium design" may additionally include a WLAN connection to enable remote control via a computer or mobile device such as a smartphone and the like.

Preferably, the first terminal fittings protrude at an angle other than 0 ° or 180 °, preferably substantially normal, or are substantially upright from a zone of the power PCB to which the current sensor is mounted. More preferably, an upper end of the first terminal fittings is preferably bent or bent substantially perpendicular to extend to an end of the PCBs. In this way, the wire of the charging cable can be readily connected to the first terminal fittings when the wire is inserted into the housing of the power supply controller, in particular substantially in a direction corresponding to the direction in which the PCBs are mounted inside the housing is.

Furthermore, it is preferable that the power supply circuit board and the control plate are mechanically connected through a plurality of columns or bolts and / or are electrically connected via a plurality of pins inserted into respective pin holes provided in the circuit boards.

In particular, since the power supply PCB and the control PCB are mechanically and electrically connected via the pillars and the pins, neither screws for the mechanical connection nor wires for the electrical connection are required.

Preferably, the pillars include a tapered end on each side and a smaller diameter portion adjacent to the tapered end for a snap fit in respective connection holes provided in the circuit boards, and / or at least a portion of the pins are collated by at least one connection bracket, and The pins are separated into functional groups that include at least one of a current sense group, a relay related group, and a display group.

Due to the snap-fit function of the columns, the two PCBs need only be pushed towards each other or (over the columns) against each other to establish the mechanical connection between the two PCBs. By providing at least one tie strap such that a group or portion of the pins are gathered, the pins are mechanically connected midway between the two PCBs to facilitate assembly of the pins and to provide a more stable mechanical connection of the pins.

Further, it is preferable that the groups are separated (or spaced apart) from each other to provide, for example, a group for current detection, a group for switching relays, and a group for operating LEDs or a display device, and the like. Accordingly, components that represent different functional elements on the PCBs may be physically separated by discrete separation or spacing of the pins into different zones (eg, zones at substantially opposite ends of the PCBs) of the PCBs to adversely affect the signals thereof and / or currents flowing therein. Furthermore, this approach is particularly advantageous in that the current detection is subject to very strict safety regulations as a result of legal safety requirements, which require closer attention.

Preferably, the first terminal fittings each include a pair of protrusion pins at least partially inserted or inserted into respective protrusion pin holes of the power lead pad, an extension portion extending from the protrusion pins (particularly, substantially straight), and a connection extension joined to the protrusion pins associated terminal fittings which are provided at the end of the wires (first portion of the charging cable) leading to the first connector.

In particular, because the pair of protrusion pins are provided at a lower end of the first terminal fittings, the first terminal fittings can be mechanically stably disposed above or on the power PCB. Any tilt or skew of the first terminal fittings is avoided by providing the pair of projection pins inserted into the respective projection pin holes of the power PCB. Furthermore, the creepage distance for surface currents is increased, which is the improved electrical safety, for example, with respect to short circuits or discharges. The extension portion may be disposed within a hole of the current sensor, in particular to avoid a separate wire or line for placement within the current sensor for detecting the current. The first terminal fitting includes a connection terminal for connection to an associated terminal fitting provided at the end of the wire leading to the first connector. Thus, the first terminal fitting performs three functions, namely, connecting to the power PCB, providing the current-sensing electrical path in the form of the extension portion, and connecting to the wire by means of the connection extension at the end opposite to the projection pins. Further, it is preferable that the extending portion stands upright from the power PCB and extends in a direction substantially perpendicular to the extending direction of the power PCB. Further, it is preferable that the connection extension is angled or curved with respect to the extension portion and extends in a direction substantially parallel to the extending direction of the power PCB.

Specifically, a plurality of relays are connected to the power supply board in the vicinity of the second terminal fittings for switching between a connected state in which the first and second terminal fittings are connected and a non-connected state in which the connection between the first and second terminal fittings is canceled; and / or the control plate is shorter than the power supply board, the plurality of relays being arranged on the power supply board adjacent to the control board such that there is no overlap between the relays and the control board is available.

Since the relays are provided in the vicinity of the second terminal fittings provided at one end of the power PCB while the first terminal fittings are provided at the opposite end thereof, the relays are far from the current sensor connected to the first terminal fittings is provided provided. Therefore, the control PCB can be stacked over the current sensor, avoiding the relays having a greater height compared to the current sensor. In particular, a compact structure can thus be achieved.

Preferably, the power supply board has a substantially rectangular shape with a length and a width, wherein the length is greater than the width, the first terminal fittings are arranged at one end in the length direction, and the second terminal fittings at the opposite end in FIG Direction of the length of the power supply circuit board are arranged.

According to another aspect, there is provided a power supply control apparatus for a charging cable particularly according to the above aspect of the invention or a particular embodiment thereof, comprising: a housing for housing a power supply board and a control panel, wherein the power supply board includes: first Terminal fittings for connection to associated terminal fittings provided at one end of wires leading to a first connector and second terminal fittings for connection to associated terminal fittings provided at one end of wires leading to a second connector, and an integrated power supply line for connection the first and second terminal fittings.

According to another aspect, there is provided a method of charging a vehicle-mounted battery, comprising the steps of: connecting a first connector to an electrical power lead, connecting a second connector to a vehicle-side connector, connecting the first and second connectors via a cable, Controlling a power supply line from the electric power supply line to the vehicle via a power supply control device provided inside the cable, connecting first terminal fittings provided on a power supply board with associated terminal fittings connected at one end to the first connector leading wires are provided, connecting second terminal fittings provided on the power supply board with associated terminal fittings disposed at one end of wires leading to the second connector n, and connecting the first and second terminal fittings via a power supply line integrated within the power supply circuit board.

According to another aspect, there is provided a method of assembling a power supply control device of a charging cable, comprising the steps of: providing a power supply board, inserting a plurality of pins into pin holes provided in the power supply board;
Inserting a plurality of pillars into communication holes provided in the power supply circuit board, attaching a control rectifier plate by inserting opposite ends of the pins into pin holes provided in the control plate and inserting opposite ones or opposite ends of the pillars in communication holes provided in the control plate and providing the power supply board with an integrated power supply line.

These and other objects, features and advantages of the present invention will become more apparent upon reading the following detailed description of preferred embodiments and the accompanying drawings. Note that notwithstanding that embodiments are described separately, individual features thereof may also be grouped into additional embodiments.

1 shows a power supply control device according to an embodiment in perspective view before assembling their components.

2 shows an assembled state of the power supply control device in perspective view.

3 FIG. 12 is a side view of the composite power supply controller of FIG 2 ,

4 shows a detail of the first terminal fittings provided within a hole of the current sensor.

5 FIG. 12 is a circuit diagram of the power supply control device according to a specific embodiment. FIG.

6 shows examples of three different control or regulator plates.

7 shows a detail of the power supply board in cross section.

8th shows the charging cable, which includes connector, and the power supply control device.

In one embodiment, a charging cable C for charging a battery installed in a vehicle, such as an electric vehicle or a hybrid vehicle, includes a first connector 10 For connection to an electrical power supply of an infrastructure, such as a building, a charging station or the like, a second connector 20 for connection to a vehicle-side connector provided in or on the vehicle, and a cable for connecting the first and second connectors 10 . 20 wherein the cable C is provided at an intermediate position or in line with a power supply controller PCSA for controlling a power supply or a current from the electric power supply to the vehicle. Specifically, the power supply controller PCSA includes a power supply board (power PCB) 100 and a control plate (control PCB) 200 at least partially in a housing 30 are housed. In particular, the power supply board includes 100 further one or more first terminal fittings 150 for connection to an associated terminal fitting (s) at or near one end of one or more wires (see L (N) i, N (L) i and PEi of FIG 6 ) is / are provided to the first connector 10 leads / leads, and one or more second terminal fittings 160 for connection to an associated terminal fitting (s) at or near one end of one or more wires (see L (N) o, N (L) o and PEo of FIG 6 ) is / are provided to the second connector 20 lead / lead. At least one power supply line is provided 190 containing the first and second terminal fittings 150 . 160 connects to the power PCB 100 in particular in the form of at least one conductive path, such as conductive traces, pads, or the like, etched from one or more conductive layers (such as copper or metal layers) attached to a non-conductive substrate of the power PCB 100 (especially with lamination on it) are provided.

As in 1 and 2 is shown is the control PCB 200 stacked on the power PCB 100 intended. Both the control PCB 200 as well as the power PCB 100 have substantially the shape of a rectangle or polygon whose length is greater than its width. In this connection, a dimension extending in the direction of the length of the PCBs becomes a longitudinal direction 1 a dimension extending in the width direction of the PCBs is referred to as a width direction w, and a dimension extending in the arrangement direction (stacking direction) of the two PCBs is referred to as a height direction h.

The power PCB includes two or more relays on one side (eg, top surface) thereof 300 as well as a housing 500 that has a current sensor 400 (please refer 4 ) surrounds. The control PCB 200 should be mechanical with the power PCB 100 by means of at least one column 600 (For example, four columns 600 ) which detects a snap fit function at opposite ends thereof. The columns 600 include a tapered end 610 at each end thereof as well as a small diameter section 620 behind the tapered end 610 , This allows the column 600 by means of locking seat in connecting holes 120 . 220 be introduced to the power PCB 100 and the control PCB 200 are provided. So the columns have to 600 only against the communication holes 120 . 220 be pressed to make a mechanical connection between the two PCBs 100 . 200 provide.

However, the invention is not limited to the use of the column / columns 600 limited. Alternatively, bolts, screws and / or manifolds and the like can be used and for the mechanical connection of the power PCB 100 and the control PCB 200 be used.

Furthermore, a plurality of pins 700 provided such that this is an electrical connection between the two PCBs 100 . 200 produce. The ends of the pins 700 are in pin holes 130 . 230 introduced to the power PCB 100 and the control PCB 200 are provided. Furthermore, the pins 700 into one or more groups (for example, three groups A, B, C), as in 1 is shown, wherein the groups A, B, C respectively by combining a plurality of pins 700 by means of one or more, in particular by means of a pair of connecting straps 710 for arranging and / or holding the pins 700 be formed in relation to each other. Preferably, a plurality of (for example, three) groups A, B, C are pins 700 away from each other to provide a required clearance between, for example, the current detection pins (Group A) and the relay-related pins (Group B) and / or the indicator pins (Group C). Accordingly, requirements regarding electromagnetic compatibility (EMC) can be readily met.

First connection fittings 150 are at an end zone (for example, a left end) of the power PCB 100 (please refer 4 ) in the longitudinal direction l and comprise at least two power supply terminals and a ground terminal (not shown). Second connection fittings 160 are at another end zone (for example, a right end) of the power PCB 100 in 1 intended. These second connection fittings 160 comprise at least two power supply terminals, a ground terminal and / or at least one signal line or a data bus.

The first connection fittings 150 are to be connected to a first section C1 of a charging cable C, which becomes a first connector 10 for connection to an infrastructure socket, such as a commercial AC socket for providing electrical power leads. The second connection fittings 160 are to be connected to a second section C2 of the charging cable C, which leads to a second connector 20 for connection with an associated vehicle-side connector on the side of the vehicle, such as an electric vehicle or a hybrid vehicle leads. Accordingly, the power supply control device is PCSA, which is the power PCB 100 and the control PCB 200 comprises, at an intermediate position (for example in the middle) of the charging cable C (between the first and second sections C1, C2 of the charging cable C) arranged to establish an electrical connection between the commercial AC power supply line and the vehicle. However, the power supply control device PCSA may also be used as a connector supply device having an integrated first connector 10 has, be formed. In this embodiment, the power supply device, which is the first connector 10 includes, to be connected to the in-box. In such a case, the first connector 10 with the power PCB 100 in particular by means of the connection fittings 150 be connected without the interposition of a wire connection.

The power PCB 100 is further provided with at least one mounting hole 110 (For example, four mounting holes 110 at or near each corner thereof) to mechanically connect to a housing 30 enable the power supply control PCSA.

As in further 4 are shown are the first terminal fittings 150 at an end portion (for example, the left end) of the power PCB 100 by at least partially inserting a pair of projection pins 152 in corresponding projection pin holes 140 that are in or on the power PCB 100 are provided provided. The first connection fittings 150 further comprise an extension portion 154 which is substantially straight up, that is, substantially straight from the projection pins 152 extends out. Furthermore, the first terminal fittings comprise 150 a connection extension 156 for connection to power cable connection adapters 180 , Preferably, the extensions are 156 about 90 ° with respect to the extension portion 154 bent so that the projections 156 extend parallel to the extension direction (longitudinal direction l) of the PCBs. Accordingly, a compact design of the power supply controller PCSA can be obtained.

The current sensor 400 surrounds the extension section 154 the first terminal fittings 150 (side) to the current that is within the extension section 154 the first fittings 150 flowing through induction, to detect. Furthermore, a housing surrounds 500 at least partially the current sensor 400 and includes a pair of connection extension housing chambers 520 and a grounding path housing chamber 530 , The housing 500 is made of a dielectric or insulating material, such as resin, for proper insulation between the two power terminals of the first terminal fittings 150 provide. In addition, the adjacent accommodation chambers 520 . 530 at least partially by at least one partition wall disposed therebetween 525 separated from each other. Accordingly, the creepage distance between adjacent terminal fittings 156 increased.

The first connection fittings 150 can be easily made by a conductive plate (for example, metal) by punching, cutting, folding or embossing and / or bending. The connection extensions 156 are outward or away from each other (see 4 ), that is, such that the connection extensions 156 at a greater distance from each other with respect to the extension portions 154 are arranged, bent. Accordingly, the ground terminal (not shown) may be at an intermediate position between the connection extensions 156 the power terminals are arranged. This allows the grounding process housing chamber 530 of the housing 500 between the two connection extension housing chambers 520 of the housing 500 be arranged.

Because the connection extensions 156 the first terminal fittings 150 extend substantially in the longitudinal direction l of the PCBs, one can obtain a low structure, thereby allowing the at least one control PCB 200 on or above the current sensor 400 and the housing 500 is stacked. How out 1 and 2 is apparent, is the pair of relays 300 in the vicinity of the second terminal fittings 160 adjacent to the control PCB 200 arranged such that no overlap between the control PCB 200 and the relay 300 is available. Accordingly, the height of the overall arrangement can be reduced.

Hereinafter, functions of the charging cable C including the power supply control device PCSA will be described 5 described.

Will be the first connector 10 of the charging cable C is connected to a power supply line of the infrastructure such as a commercial AC socket for providing electric power, the first connector connects 10 the first connection fittings 150 the power PCB 100 with the electrical power supply via the first section C1 of the charging cable C. As is known, such a commercial AC electric power supply line comprises at least two power terminals L and N and a ground terminal PE, wherein the voltage is in particular between approximately 100 V and 250 V.

Furthermore, the second connector 20 be connected to an associated vehicle-side connector to the vehicle-side connector with the second terminal fittings 160 the power PCB 100 connect to. In an initial phase, the connections of the first and second terminal fittings are 150 . 160 electrically by means of the relays 300 , as in 5 is shown, separated. Furthermore, the ground terminal PE is connected to the ground terminal PE of the vehicle.

In addition, a signal line CP is connected to the vehicle. In the event that a control device and / or a charging device provided within the vehicle, a signal via the signal line CP for a CP interface 280 provided within the power supply control device PCSA indicating that charging is required and. should be started, provides the CP interface 280 a signal for the controller or a microcontroller 260 ready to start or initiate the loading process. In response to the signal to begin or initiate the charging process, the controller adjusts 260 a signal for a relay driver 310 ready to the relay switch 320 close.

Are the relay switches 320 the relay 300 closed, the lines L and N are brought into a connected state so as to supply an electric power supply from the AC outlet through the first terminal fittings 150 , the lines L and N and the second terminal fittings 160 to allow the vehicle.

In this connected state, the current sensor detects 400 the power to the vehicle (for example, via the first terminal fittings 150 ), induces a current in the (in particular solenoid-type or ferrite core-like) current sensor 400 and / or provides a signal for a current sensor control part 410 ready with the Control 260 communicated. In the event that the current exceeds a specified (predetermined or predeterminable) threshold, the controller gives 260 a respective signal to the controller or regulation 260 to operate the relay driver 310 off to the relay switch 320 the relay 300 open and interrupt the flow of electricity to the vehicle. Thus, too high a power for safety reasons can be avoided.

Furthermore, the controller 260 in particular with a signal conditioning temperature sensor 250 connected to compensate for various signals with respect to the ambient temperature.

Another signal is in particular from a voltage monitoring AC 290 provided with the control 260 communicates to monitor the voltage provided. In the case of too high a voltage, which may cause damage to the charging cable C and / or the electronic components provided inside the power supply control device PCSA and / or the vehicle, the relay switches become 320 the relay 300 also open to disconnect the vehicle from the electrical power supply in response to a signal from the controller 260 for the relay driver 310 via the control or regulation 260 provided.

In particular, a display device 270 provided to display information for a user. As in 2 is shown, such a display device 270 one or more (for example three) LEDs 270a to 270c for indicating respective (eg three) different states. The first LED 270a may be green and indicate a standby state while the second LED 270 can be yellow, indicating that charging is in progress, and the third LED 270c may be red, indicating that a defect has occurred. A leakage current can also be detected by the current sensor 400 be detected to stop the operation and a defect by the third LED 270c in the event that the leakage current exceeds a specified (predetermined or predeterminable) threshold.

Preferably, the control or Regelelleiterplatte 200 from a plurality of control or Regiteriterplatten 200a . 200b . 200c with different layout, like in 6 shown is selected. Accordingly, the same components in the first and second connectors 10 . 20 , the cable, the housing 30 and the power supply board 100 at various control or Regelleiterplatten 200a . 200b . 200c can be used to provide various power supply charging cables C. For example, a "basic design" may be an advertisement 270 , LEDs, for example, to indicate functions and / or charging issues, while a "comfort design" additionally includes multiple buttons 272 for selecting between different charging modes or for controlling the charging time period and the like. A "premium design" can additionally a WLAN connection 274 to enable remote control via a computer or a mobile device such as a smartphone and the like.

7 shows a detail of the power supply board 100 in cross section. The current sensor 400 is on an element surface (for example, an upper surface) of the power supply board 100 mounted and at least partially in the current sensor housing chamber 510 of the housing 500 accommodated. The first connection fittings 150 are also at least partially within the housing 500 housed such that the extension portion 154 hereof within the current sensor 400 (For example, within a substantially annular hole in the sensor 400 is provided) in order to induce a current electromagnetically in particular whenever a current through the first terminal fittings 150 flows. The first terminal fitting (s) 150 can with the power cable connection fitting / power cable fitting 180 be connected at the end of the first section C1 of the cable C.

Furthermore, the one or more protrusion pins 152 of the first terminal fitting (s) 150 at least partially into the pin holes 140 the power supply board 100 introduced and electrically connected to the power supply line 190 (For example, by a soldering, not shown), which is provided thereon or integrated therein (in particular on one side substantially opposite or opposite to the element surface), in particular in the form of at least one conductive path, such as conductive paths, for example made of a metal like copper. Accordingly, the first terminal fittings 150 electrically with the second terminal fittings 160 via the power supply line 190 connected to the power supply board 100 integrated or integrally (unitary) is provided on it, which is why in particular no additional busbar, no additional cable or the like is required. In order to The power supply controller PCSA is small in size and can be manufactured with a minimum of components. Furthermore, the assembly process described below is simplified.

8th shows the entire charging cable C in perspective view. The power supply control device PCSA is with the housing 30 housed or provided with a lid 32 having, preferably with the housing 30 is assembled by means of locking seat (not shown) and / or by means of one or more screws. As in further 8th shown is the lid 32 with one or more, in particular a plurality of openings 32 to accommodate one or more respective advertisements 270a . 270b . 270c (For example, LEDs), on the control or regulator plate 200 are provided provided. Because the two PCBs 100 . 200 (in particular, the relay 300 on the power PCB 100 in a position laterally protruding on one side of the power PCB 200 can be provided stacked, one can get a very compact Leistungszuleitungssteuer- or regulating device PCSA. Further, since no further bus bars or cables are required within the power supply controller PCSA, the compactness can be further improved while still allowing a simple and error-resistant assembling procedure (to be described later).

The assembling procedure of the power supply controller PCSA will be described below. In a first step, the power supply board becomes 100 manufactured having the integrated power supply line or a conductive power path for connecting the first and second terminal fittings 150 . 160 contains. The conductive power path is provided as a thick film path having a thickness in a range of between about 50 μm and about 120 μm, preferably between about 70 μm and about 110 μm, and optimally between about 80 μm and about 100 μm. Accordingly, currents in a range between about 4 A and about 13 A can be supplied via the conductive power path. Preferably, the supplied current is in a range between about 6 A and about 10 A, optimally between about 7 A and about 9 A.

In a next step, a plurality of electrical pins 700 in the pin holes 130 introduced in the power PCB 100 are provided. Furthermore, a plurality of columns 600 in communication holes 120 introduced in the power PCB 100 are provided, and it will be the pillars 600 against the power PCB 100 pressed to keep them in snap fit with the columns 600 in the connection holes 120 reach.

In a next step, the control PCB becomes 200 at the upper or distal ends of the pins 700 and the columns 600 mounted (in particular pressed against) to at least partially the upper or distal ends of the pins 700 and the columns 600 in respective pin holes 230 and / or communication holes 220 the control PCB 200 introduce.

Furthermore, the ends of the pins 700 electrically with the respective conductive paths of the PCBs 100 . 200 electrically connected (in particular by soldering) to the electrical connection between the two PCBs 100 . 200 manufacture. It is also possible to have releasable fasteners (such as pin connectors) on the power PCB 100 and / or the control PCB 200 provide a releasable electrical connection of the two PCBs 100 . 200 over the pins 700 to enable.

Finally, the two PCBs 100 . 200 comprehensive arrangement within the housing 300 housed, and it will be the lid 32 closed and fixed over a locking seat and / or one or more screws.

Furthermore, the current sensor 400 , the case 500 , the first connection fittings 150 as well as the second connection fittings 160 on the power PCB 100 assembled. The first and second terminal fittings 150 . 160 are also electrically (especially by soldering) with conductive paths attached to the power PCB 100 are provided connected.

Although not shown, the power supply controller PCSA may further include one or more operation elements (such as buttons, a touch display, or the like) for operation by a user, thereby providing operation signals to the controller 260 for example, to turn the charging cable C on and off and to switch between different operating states that provide different charging currents and charging periods. In addition, the display device 270 additional LEDs and / or a screen (such as an LCD screen) for displaying information to a user, such as a charging current and an expected charging end time. In another embodiment, the power supply controller PCSA may include a wireless local area network (WLAN) connection for connection to a computer or a mobile device, such as an operator's smartphone. This wireless connection can be used to update the software of the controller 260 and / or used to monitor and control the charging process of the charging cable.

In particular, since the power supply control device PCSA does not include flat cables, flexible PCBs, bus bars, wires, and the like, the power supply control device PCSA can be readily assembled, and the size thereof can be minimized. In particular, the specific two-layer form that carries the two PCBs 100 . 200 stacked on top of each other, to a low-level power supply controller PCSA. In this context, the dimension that extends between one end of the substantially rectangular power PCB 100 in the longer dimension than the length of the power PCB 100 defines a dimension of the shorter side of the power PCB 100 as the width of the power PCB 100 is defined. Furthermore, the height of the direction is defined as the direction perpendicular to the length and perpendicular to the width.

LIST OF REFERENCE NUMBERS

10

first connector

20

second connector

30

casing

32

cover

32a

opening

100

Power supply circuit board

110

mounting hole

120

connecting hole

130

pinhole

140

Lead pinhole

150

first connection fitting

152

lead pencil

154

extending portion

156

Connecting projection

160

second connection fitting

162

Connecting projection

180

Power cable terminal fitting

190

Power supply line

200 (200a, 200b, 200c)

Control or Regelleiterplatte

220

connecting hole

230

pinhole

240

Control or Regelleiterplattenleistungszuleitung

250

Signal conditioning temperature sensor

260

Control

270

Display (LED)

270a

Ready (green) indicator

270b

Display "Load" (yellow)

270c

Display "defect" (red)

272

button

274

Wireless LAN (WLAN)

280

Vehicle interface

290

voltage monitoring

300

relay

310

relay driver

320

relay switch

400

current sensor

410

Current sensor control or control part

500

casing

510

Current sensor accommodating chamber

520

Connecting projection accommodating chamber

530

Grounding extension accommodating chamber

600

pillar

610

rejuvenated end

620

smaller diameter section

700

pen

710

connecting brackets

L, N _l

Power line input

PE _l

Grounding line input

L, N _o

Power line output

PE _o

Grounding line output

l

longitudinal direction

w

width direction

H

height direction

C

charge cable

C1

first section

C2

second part

PCSA

Power supply control device

Claims (10)

Charging cable (C) for charging a battery installed in a vehicle, comprising a first connector ( 10 ) for connection to an electrical power supply line, a second connector ( 20 ) for connection to a vehicle-side connector, a cable for connecting the first and second connectors ( 10 . 20 ), the cable having a power supply controller (PCSA) for Controlling a power supply line from the electric power supply line to the vehicle, the power supply control device (PCSA) comprising: a housing ( 30 ) for accommodating a power supply circuit board ( 100 ) and a control or regulator plate ( 200 ), wherein the power supply board ( 100 ) includes: first terminal fittings ( 150 ) for connection with associated connection fittings ( 180 ) located at one end to the first connector ( 10 ) leading wires are provided, and second terminal fittings ( 160 ) for connection to associated terminal fittings located at one end to the second connector ( 20 ) leading wires are provided, and a power supply line ( 190 ) for connecting the first and second terminal fittings ( 150 . 160 ), wherein the power supply line ( 190 ) as at least one conductive path of the power supply board ( 100 ) is trained. Charging cable according to claim 1, wherein the first terminal fittings ( 150 ) from a current sensor ( 400 ) for controlling one of the power supply board ( 100 ) are supplied surrounded and / or the control or Regelereiterplatte ( 200 ) from a plurality of control or reference plates ( 200a . 200b . 200c ) is selected with different layout. Charging cable according to claim 1 or 2, wherein the power supply circuit board ( 100 ) and the control or regulator plate ( 200 ) mechanically via a plurality of columns ( 600 ) and / or electrically via a plurality of pins ( 700 ) provided in printed circuit boards respective pin holes (FIG. 130 ) are connected. Charging cable according to claim 3, wherein the columns ( 600 ) a tapered end ( 610 ) on each side and a smaller diameter portion ( 620 ) adjacent to the tapered end for a snap fit in in the printed circuit boards ( 100 . 200 ) provided respective connection holes ( 120 . 220 ) and / or at least part of the pens ( 700 ) by at least one connecting bracket ( 710 ) and / or the pens ( 700 ) are separated into functional groups including at least one of a current detection group (A), a relay related group (C), and a display group (B). Charging cable according to one of the preceding claims, wherein the first terminal fittings ( 150 ) each comprise: a pair of protrusion pins ( 152 ) inserted into respective boss pin holes ( 140 ) of the power supply board ( 100 ) are or are to be introduced, an extension section ( 154 ) extending from the projection pins ( 152 ) extends substantially straight, and a connection extension ( 156 ), with the associated connection fittings ( 180 ) provided at the end of the wires leading to the first connector, connected or to be connected. Charging cable according to one of the preceding claims, wherein a plurality of relays ( 300 ) on the power supply board ( 100 ) in the vicinity of the second terminal fittings ( 160 ) is provided for switching between a connected state in which the first and second terminal fittings ( 150 . 160 ) and a non-connected state in which the connection between the first and second terminal fittings ( 150 . 160 ), and / or the control or regulator plate ( 200 ) shorter than the power supply board ( 100 ) and the plurality of relays ( 300 ) on the power supply board ( 100 ) adjacent to the control or regulator plate ( 200 ) is arranged such that no overlap between the relay ( 300 ) and the control or regulator plate ( 200 ) is available. Charging cable according to one of the preceding claims, wherein the power supply printed circuit board ( 100 ) has a substantially rectangular shape with a length and a width, wherein the length is greater than the width, and the first terminal fittings ( 150 ) are arranged at one end in the direction of the length and the second terminal fittings ( 160 ) at the opposite end in the direction of the length of the power supply circuit board ( 100 ) are arranged. A power supply control device (PCSA) for a charging cable, comprising: a housing ( 30 ) for accommodating a power supply circuit board ( 100 ) and a control or regulator plate ( 200 ), wherein the power supply board ( 100 ) includes: first terminal fittings ( 150 ) for connection with associated connection fittings ( 180 ) connected at one end to a first connector ( 10 ) leading wires are provided, and second terminal fittings ( 160 ) for connection to associated terminal fittings located at one end of a second connector ( 20 ) leading wires are provided, and a power supply line ( 190 ) for connecting the first and second terminal fittings ( 150 . 160 ), wherein the power supply line ( 190 ) as a conductive path of the power supply board ( 100 ) is trained. A method of charging a vehicle-mounted battery, comprising the steps of: Connecting a first connector ( 10 ) with an electrical power supply line, connecting a second connector ( 20 ) with a vehicle-side connector, connecting the first and second connectors ( 10 . 20 ) via a cable, controlling a power supply line from the electric power supply line to the vehicle via a power supply control device (PCSA) provided inside the cable, connecting first terminal fittings ( 150 ) connected to a power supply board ( 100 ) are provided, with associated connection fittings ( 180 ) located at one end to the first connector ( 10 leading wires are provided, connecting second terminal fittings ( 160 ) connected to the power supply board ( 100 ) are provided with associated terminal fittings at one end of the second connector ( 20 ) leading wires are provided, and connecting the first and second terminal fittings ( 150 . 160 ) via a power supply line ( 190 ) inside the power supply board ( 100 ), wherein the power supply line ( 190 ) as a conductive path of the power supply board ( 100 ) is trained. A method for assembling a power supply control device (PCSA) of a charging cable (C), comprising the following steps: providing a power supply circuit board ( 100 ), Inserting a plurality of pens ( 700 ) in pin holes ( 130 ) in the power supply board ( 100 ), inserting a plurality of columns ( 600 ) in communication holes ( 120 ) in the power supply board ( 100 ), attaching a control or Regiteriterplatte ( 200 ) by inserting opposite or opposite ends of the pins ( 700 ) in pin holes ( 230 ) located in the control or regulator ( 200 ) are provided, and insertion of opposite or opposite ends of the columns ( 600 ) in communication holes ( 220 ) located in the control or regulator ( 200 ), and providing the power supply board ( 100 ) with an integrated power supply line ( 190 ), wherein the power supply line ( 190 ) as a conductive path of the power supply board ( 100 ) is trained.

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