DE102016224103A1 - Power supply system, supply line and connection cable - Google Patents

Abstract

The invention relates to a power supply system, in particular a charging system for a hybrid or electric vehicle, comprising a supply unit with an electrical energy source, a consumer unit with an energy sink and a supply line with a connection cable.

Description

The invention relates to a power supply system, in particular a charging system for a hybrid or electric vehicle, comprising a supply unit with an electrical energy source, a consumer unit with an energy sink and a supply line with a connection cable.

The spread of electric vehicles has recently increased significantly and it can be assumed that this trend will continue. For the everyday suitability of electric vehicles is of great importance that their batteries can be charged at any time as easy and fast. For this purpose, specially adapted charging stations for electric vehicles, the so-called charging stations, have been developed. These are characterized among other things by high charging currents and high power transmissions.

Proceeding from this, the present invention seeks to provide an advantageous ausgestaltetes power supply system and an advantageously designed supply line and / or an advantageously designed connection cable.

This object is achieved by a power supply system having the features of claim 1, by a supply line with the features of claim 15 and by a connecting cable with the features of claim 17. Preferred developments are contained in the dependent claims. The advantages and preferred embodiments stated with regard to the supply line and / or the connecting cable can also be applied to the power supply system and vice versa.

A corresponding power supply system is designed in particular as a charging system for a hybrid or electric vehicle and has a supply unit, such as a charging station, a charging station or a charging station, with an electrical energy source, a consumer unit, so for example a hybrid or an electric vehicle, with a Energy sink, in particular an accumulator, and a supply line with a connection cable. In this case, the supply unit and the consumer unit can be coupled via the connecting cable for the purpose of transmitting electrical energy from the energy source via the supply line to the energy sink and, moreover, the power supply system has a control unit for controlling the transmission of electrical energy.

Furthermore, the power supply system preferably comprises a control circuit for controlling the transmission of electrical energy such that the control in response to at least one state information about the state of at least a portion of the supply line, so for example via the state of the connection cable, and in particular as a function of at least one state information the condition of the entire supply line takes place.

Corresponding state information is typically determined by means of a sensor system or a sensor system, for example for detecting temperature, mechanical load and / or media intrusion, and subsequently used as a basis for the control. Such a sensor system is embodied, for example, by at least one additional measuring element, such as a fiber-optic line, which is appropriately integrated into the supply line, and optionally by an evaluation unit. Alternatively or additionally, corresponding state information is obtained from a data source with the aid of an electronic query unit.

As a result, for example, different state profiles are created, for example, a punktuelles, one over a longer section ersteckendes temperature profile or over the whole line ersteckendes temperature profile for optimal, fastest possible charging as input to regulate a power transfer and / or Serve control of any existing cooling circuit. Accordingly, then also typically a regulation in the true sense of this term and not just a start and stop.

In particular, in the case of a power supply system with charging station and hybrid or electric vehicle, it is advantageous to design the sensor so that this extends into the vehicle and housed therein power (further) leading lines to the charging system from the charging station to to monitor and tune to the battery of the hybrid or electric vehicle.

The control unit preferably forms, inter alia, the control circuit and, moreover, the control circuit advantageously has a sensor system connected to the control unit for determining the status information. The control unit is typically arranged in the supply unit, that is to say for example in a charging station. If an electronic interrogation unit is also provided in such a case, it is preferably set up to obtain status information from a consumer unit, that is to say in particular from a hybrid or an electric vehicle, and accordingly the consumer unit has an interrogation unit in such a case couplable response unit. The interrogation unit and the response unit then allow communication of the supply unit and the consumer unit in the coupled state.

To determine state information, the sensor system preferably also has at least one sensor, which is integrated in particular at a predetermined position in an intermediate region between the ends of the connecting cable in the connecting cable. In an advantageous embodiment, the connection cable also has a further sensor, which is positioned at one end of the connection cable and is integrated, for example, in a connector.

Furthermore, an embodiment of the sensor system is favorable, which makes it possible to determine status information along the connecting cable and in particular along the entire supply line. For this purpose, the sensor system has, for example, a plurality of sensors positioned along the connection cable and integrated in the connection cable. Alternatively or additionally, the detection of state information does not take place punctually at a plurality of discrete positions, but quasi-continuously along a measuring path, which extends in particular along the connecting cable and extends for example over the entire length of the connecting cable or beyond. According to one embodiment, the measuring section extends over almost the entire length of the supply line.

In particular, when such a measuring section is to be realized, it is advantageous if the sensor system has at least one fiber-optic sensor which is set up, for example, for a spatially resolved temperature measurement.

Regardless of the design of the sensor system, it is particularly favorable for safety reasons, if this is set up to determine the surface temperature of the connecting cable as state information. In this case, a maximum surface temperature of, for example, 60 ° Celsius is then typically specified for the connecting cable and the control circuit then controls the electrical power flowing through the connecting cable such that the predetermined maximum surface temperature is not exceeded.

Furthermore, the power supply system advantageously has a cooling circuit with a coolant guide formed at least in the coupled state of the supply unit and the consumer unit, wherein the coolant guide is at least partially integrated into the connection cable, so that at least the connection cable is cooled during a transmission of electrical energy.

Alternatively or additionally, the power supply system, at least in the decoupled state of supply unit and consumer unit on two separate cooling circuits, in which case preferably a cooling circuit is integrated into the supply unit and a cooling circuit in the consumer unit. In this case, the cooling circuit of the supply unit is further preferably designed for cooling at least the connecting cable, and accordingly the coolant guide integrated at least partially into the connecting cable is then part of this cooling circuit. This can then be operated in the decoupled state of supply unit and consumer unit and advantageously takes place cooling at least the connection cable after completion of a power transmission, for example, until the connection cable is cooled down to a predetermined temperature.

By a corresponding cooling circuit or corresponding cooling circuits can then, for example, given for the connection cable maximum surface temperature of, for example, 60 ° C, larger currents through the connecting cable, as in a non-cooled or passive, cooled by the ambient air connection cable of the case would.

A corresponding connection cable is hereby typically designed as a high-current cable and expediently designed for currents greater than 5 A, preferably greater than 10 A, more preferably greater than 50 A and in particular greater than 100 A. In addition, the connecting cable is preferably designed for currents less than 1000 A and in particular less than 500 A. A corresponding connection cable is therefore preferably designed for a current intensity which is in the range between 10 A and 1000 A, and in particular in the range between 100 A and 500 A. In addition, such a connection cable is designed according to an advantageous embodiment for direct currents, ie in particular as Charging cable for a DC charging. A corresponding DC charging then takes place, for example, at 1000 V with 450 A.

The coolant guide is expediently designed at least in sections as an elongated, in particular tubular, heat exchanger and preferably extends at least in a section along the connecting cable. That is, at least a portion of the coolant guide of the cooling circuit is formed as a type of hose integrated into the connection cable, which preferably extends over the entire length of the connection cable.

In an advantageous development, in addition to the at least one integrated section of the coolant guide, a further section of the coolant guide separated therefrom is integrated into the connecting cable, whereby this further section is preferably tubular and preferably extends along the connecting cable over its entire length , In a connecting cable designed in this way, the cooling circuit is then preferably designed such that, during operation of the cooling circuit, a flow and a return for a coolant are formed in the connecting cable through the mutually separate sections of the coolant guide.

Another advantage is an embodiment of the supply line, in which this has a separating point formed by two complementary and in particular complementary connector, which is arranged at one end of the connecting cable, which is part of the supply line. In this case, then the two connectors expediently have complementary electrical contacts for the transfer of electrical power, so that in coupled connectors electrical power can be transmitted across the separation point away. The supply line and / or the connecting cable then expediently have wires connected to these electrical contacts for the transmission of electrical power.

Further, it is advantageous if the two connectors have complementary coolant connections for a coolant transfer, in which case a variant is preferred in which the two connectors have complementary coolant connections for a coolant transfer via a flow on the one hand and a return on the other. In this case, the two connectors then typically have at least two separate coolant connections. The supply line and / or the connecting cable then in turn has expediently coolant guides connected to these coolant connections for the passage of a coolant.

For a simple handling of the power supply system, an embodiment of the plug connector is also advantageous in which a valve, in particular a changeover valve and / or a controllable valve, is integrated in at least one coolant connection of a connector and preferably in each coolant connection of the two plug connectors ., Which prevents leakage of the coolant in separate connectors or prevent. With the help of a switching valve can also achieve that a shortened cooling circuit in the decoupled state of supply unit and consumer unit is still operable or that a continuous cooling circuit is divided into two separate cooling circuits, which can be operated independently and subsequently in the coupled state of supply unit and consumer unit connected to a cooling circuit.

Also favorable is an embodiment of the power supply system in which the two connectors complementary contacts, such as electrical contacts or optical interface elements, for the transfer of information signals, in particular for the transfer of information signals described above, have, for example, a communication or data exchange between the Supply unit and the consumer unit allow. In this case, then corresponding signal lines or data lines are integrated into the connection cable and / or in the supply line, which are connected to the contacts for the transfer of information signals.

Since expediently differently configured connectors are advantageous for different applications and application scenarios, which differ in particular with respect to the design and the number of contacts and / or the coolant connections, it is further advantageous to code the connectors by their contacts and / or connections, so that only compatible connectors can be connected together. With a corresponding coding of the plug can be alternatively or additionally this at a plug the cooling capacity and / or the charging power, for example, by the number of contacts set. Here, the connectors, at least in terms of electrical contacts for the transfer of electrical power, preferably according to the Standard IEC 62196-2 (or SAE J1772-2009) or according to the Standard EN 62196 designed.

Another advantage is an embodiment of the power supply system, in which a portion of the coolant supply of the cooling circuit from the separation point to the energy sink out, so for example up to an accumulator out extends. In this case, then preferably at least a portion of the current path is cooled within the consumer unit towards the energy sink in the operation of the cooling circuit.

Alternatively or additionally, a section of the coolant guide of the cooling circuit extends from the separation point to the energy source, wherein in this case, during operation of the cooling circuit, preferably at least a part of the current path is cooled within the supply unit to the energy source.

In an advantageous development, a continuous section of the coolant guide of the cooling circuit then runs along the entire current path from the energy source to the energy sink, and accordingly during operation of the cooling circuit the power supply system is cooled along this current path.

In particular, if such a continuous cooling device is given, then it is also expedient to form the cooling circuit for cooling the energy sink, that is, for example, a rechargeable battery, so that the energy sink is also co-cooled during operation of the cooling circuit.

If, on the other hand, no continuous coolant supply of the cooling circuit is provided along the entire current path from the energy source to the energy sink, a reversal point for the coolant is advantageously predetermined at a predetermined position along this path, in particular by a reversal element integrated in the connection line and preferably in the connection cable. such as a U-shaped piece of hose, which connects the two separate in the connecting line or in the connecting cable coolant guides for flow and return together.

Also useful is an embodiment of the cooling circuit, in which this has a coolant pump, which is arranged for example in the supply unit or the consumer unit and accordingly integrated in the supply unit or in the consumer unit. Accordingly, the cooling circuit is preferably designed as an active cooling circuit, which is also preferably controllable and in this case has a control unit described above.

A corresponding control unit is preferably arranged to control the cooling power and / or to regulate the charging power, that is, to regulate the electrical power that is transmitted from the power source via the supply line to the energy sink, and in particular forms the previously described control circuit. In this case, the corresponding control unit is arranged for example in the supply unit or the consumer unit and in particular designed to automatically interrupt or stop a transmission of electrical power, that is, for example, a charging operation in the event of a fault.

It is also advantageous if the power supply system and in particular the cooling circuit comprises a sensor system, ie in particular a previously described sensor system, by means of which state information, ie information on the state of the power supply system or the cooling circuit, are determined or detected. A control unit described above is also preferably part of the sensor system and accordingly connected via a signal line or a data line with one or more sensors, such as temperature sensors. In this case, in particular, an embodiment of the sensor system in which state information is determined or detected at several points along the coolant guide of the cooling circuit is expedient, for example, by a plurality of sensors distributed along the coolant guide.

It is also expedient if the cooling circuit has a cooling unit for heat extraction from the cooling circuit, so for example a heat exchanger for heat dissipation to the environment. Alternatively or additionally, the cooling circuit as a cooling unit, a condenser, an evaporator, that is, for example, an evaporator of a refrigeration cycle, and / or a heat storage, for example, a latent heat storage.

If a motor vehicle forms the consumer unit, then it is also advantageous if the cooling circuit has a heat exchanger for dissipating heat to the motor vehicle in order, for example, to heat a passenger compartment and / or to preheat assemblies, such as the oil circuit of an internal combustion engine.

• 1 in einer Art Blockschaltbilddarstellung ein Stromversorgungssystem mit einer ein Verbindungskabel mit Steckverbinder aufweisenden Versorgungsleitung sowie
• 2 in einer Seitenansicht der Steckverbinder.

Embodiments of the invention will be explained in more detail with reference to a schematic drawing. Show:

• 1 in a kind of block diagram representation of a power supply system with a connection cable with a connector having supply line and
• 2 in a side view of the connector.

Corresponding parts are provided in all figures with the same reference numerals.

An example described below and in 1 sketched power supply system 2 has a supply unit 4 with an electrical energy source 6 , a consumer unit 8th with an energy sink 10 as well as a supply line 12 with a connection cable 14 on.

Here is the power supply system 2 preferably designed as a charging system for a hybrid or electric vehicle and in this case forms a Charging station or charging station the supply unit 4 and a hybrid or electric vehicle the consumer unit 8th out. Furthermore, in such a case, an accumulator forms the energy sink 10 off and the electrical energy source 6 is typically formed in such a case by a mains connection to a supply network.

Next points the supply line 12 a separating point formed by two complementary connectors 16 on, in the embodiment according to 1 one of these connectors as a plug 18 and the other of the two connectors as a socket 20 is trained. That jack 20 is part of the consumer unit 8th and, for example, on the outside of an outer skin of the consumer unit 8th positioned. The plug 18 In turn, in the embodiment part of the connection cable 14 and forms one end of the connection cable 14 out. The connection cable 14 in turn is part of the supply line 12 and in the embodiment according to 1 also part of the supply unit 4 ,

Are the two connectors of the separation point 16 connected to each other, so are the supply unit 4 and the consumer unit 8th coupled and thus are the source of electrical energy 6 and the energy sink 10 over the supply line 12 interconnected so that via the supply line 12 electrical power from the electrical energy source 6 can be transferred to the energy sink 10.

A corresponding energy transfer is in the embodiment by connecting both connectors of the separation point 16 started and subsequently by a control unit 22 controlled in either the consumer unit 8th or, as in the case of execution according to 1 , in the supply unit 4 is housed. That control unit 22 is preferably configured such that it controls a corresponding power transmission in dependence on sensor data and accordingly, the power supply system 2 preferably at least one with the control unit 22 at least during a power transmission connected sensor 24 on, which is formed for example as a temperature sensor and positioned at a predetermined position along the supply line 12.

According to a further embodiment variant, which is not explicitly shown, at least one fiber optic line is inserted into the connection cable for generating sensor data 14 or the entire supply line 12 integrated along the connecting cable 14 or the supply line 12 runs and in particular mitausbildet a fiber optic sensor.

Alternatively or in addition to this, as in the embodiment according to 1 , several sensors 24 , For example, a plurality of temperature sensors and / or a plurality of different sensors 24 , along the current path between the electrical energy source 6 and the energy sink 10 arranged so that at least in the coupled state of supply unit 4 and consumer unit 8th by means of which state information is acquired along the corresponding current path. The transmission of corresponding state information or sensor data is preferably carried out via at least one signal line or a data line 25 , wherein more preferably at least a portion of the data line 25 into the supply line 12 is integrated, in particular such that this section through the connecting cable 14 runs, ie in the connection cable 14 is intergrated.

That is, preferably at least the connection cable 14 has at least one wire for the transmission of electrical power and at least one signal line or wire for the transmission of information signals. In this case, then also the two connectors point the separation point 16 complementary electrical contacts 26 for the transfer of electrical power on the one hand and contacts 27 , in particular electrical contacts 27 , on the other hand, for transferring information signals. This fact is in 2 indicated. In this way is then in the coupled state of supply unit 4 and consumer unit 8th both a power transmission between supply unit 4 and consumer unit 8th allows as well as communication between the supply unit 4 and consumer unit 8th or communication between sensors 24 and the control unit 22 ,

Next points the power supply system 2 in the exemplary embodiment, at least in the coupled state of the supply unit 4 and consumer unit 8th trained cooling circuit 28 with a coolant guide 29 on, wherein at least a portion of the coolant guide 29 in the connection cable 14 is integrated, so that at least the connection cable 14 is cooled during a transmission of electrical energy.

The one in the connecting cable 14 integrated section of the coolant supply 29 is preferably designed as a tubular heat exchanger and typically extends along the connecting cable 14 over its entire length. In an advantageous embodiment, at least a portion of the coolant guide also extends 29 along the entire current path from the electrical energy source 6 to the energy sink 10 and accordingly, then during operation of the refrigeration cycle 28 a coolant through the two connectors through, so on the separation point 16 away, driven. For this purpose, then point the two connectors of the separation point 16 So the plug 18 and the socket 20 , complementary coolant connections 30 on, in the preferred valves 32 integrated, which prevent leakage of the coolant, if the two connectors of the separation point 16 are separated. Corresponding coolant connections 30 are in the representation of the plug 18 according to 2 indicated. Here is a coolant connection 30 for a flow and a coolant connection 30 provided for a return and trained. In addition, this connector has 18 a protective or ground conductor 31 on.

Furthermore, the Kühlkreisaufel 28 of the power system 2 typically a refrigeration unit, which as ambient heat exchanger 34 designed for heat dissipation to the environment and, for example, in the supply unit 4 is arranged. Alternatively or additionally, the cooling circuit 28 has a particular in the consumer unit 8th arranged heat storage 36 on, which at least temporarily acts as a cooling unit.

Is the consumer unit 8th formed by a hybrid or electric vehicle, so it is also advantageous if the cooling circuit 28 an internal heat exchanger 38 has, over the heat from the cooling circuit 28 in the hybrid or electric vehicle is transferable, for example, to heat a passenger compartment or preheat an oil circuit of an internal combustion engine.

The cooling circuit 28 furthermore typically has one in particular by the control unit 22 controlled coolant pump 40 on. In addition, in the exemplary embodiment, an additional heat exchanger 42 part of the cooling circuit 28 , with which in the operation of the cooling circuit 28 the energy sink 10 , For example, an accumulator, is cooled.

The invention is not limited to the embodiment described above. Rather, other variants of the invention can be derived therefrom by the person skilled in the art without departing from the subject matter of the invention. In particular, all the individual features described in connection with the exemplary embodiment can also be combined with each other in other ways, without departing from the subject matter of the invention.

QUOTES INCLUDE IN THE DESCRIPTION

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

Cited non-patent literature

• Standard IEC 62196-2 [0025]
• Standard EN 62196 [0025]

Claims (29)

Power supply system, in particular charging system for a hybrid or electric vehicle, comprising a supply unit with an electrical energy source, - a consumer unit with an energy sink as well - A supply line with a connection cable, wherein the supply unit and the consumer unit via the connecting cable for the purpose of transmitting electrical energy from the power source via the supply line to the Energiesenke are coupled, and comprising a control unit for controlling the transmission of electrical energy. Power supply system after Claim 1 comprising a control circuit for regulating the transmission of electrical energy in such a way that the control takes place as a function of at least one state information about the state of the connecting cable and in particular as a function of at least one state information about the state of the entire supply line, wherein the control unit mitausbildet the control loop and wherein the Control circuit has a connected to the control unit sensor system for determining the state information. Power supply system after Claim 2 wherein the sensor system comprises at least one sensor integrated in the connection cable at a predetermined position in an intermediate region between the ends of the connection cable. Power supply system after Claim 2 or 3 wherein the sensor system is designed to determine status information along the connection cable and in particular along the entire supply line. Power supply system after Claim 4 wherein the sensor system comprises a plurality of sensors positioned along the patch cable and integrated into the patch cord. Power supply system according to one of Claims 4 to 5 wherein the sensor system is arranged to detect state information along a measurement path that runs along the connection cable and in particular extends over the entire length of the connection cable and beyond. Power supply system according to one of Claims 2 to 6 , wherein the sensor system has at least one fiber-optic sensor and in particular is set up for a spatially resolved temperature measurement. Power supply system according to one of Claims 2 to 7 , wherein the sensor system for determining the surface temperature of the connection cable is set as state information. Power supply system according to one of Claims 1 to 8th comprising, at least in the coupled state of supply unit and consumer unit designed cooling circuit with a coolant guide, wherein the coolant guide is at least partially integrated into the connection cable, so that at least the connection cable is cooled during a transmission of electrical energy. Power supply system after Claim 9 wherein the control unit is arranged to control the cooling circuit and wherein in particular the control loop is arranged to control the cooling capacity of the cooling circuit. Power supply system after Claim 9 or 10 in that the supply line has a separation point formed by two, in particular complementary, connectors, which is arranged at one end of the connection cable, and wherein the two connectors have electrical contacts for the transfer of electrical power. Power supply system according to one of Claims 9 to 11 wherein the two connectors have coolant connections for a coolant transfer. Power supply system according to one of Claims 9 to 12 wherein the two connectors coolant connections for a coolant transfer via a flow on the one hand and a return on the other. Power supply system according to one of Claims 9 to 13 wherein the two connectors have contacts, in particular electrical contacts, for the transmission of information signals. Power supply system according to one of Claims 9 to 14 , wherein in at least one coolant connection of at least one connector, a valve and in particular a controllable valve is integrated. Power supply system according to one of Claims 9 to 15 wherein a portion of the coolant duct of the refrigeration cycle extends from the separation point to the energy sink. Power supply system according to one of Claims 9 to 16 wherein a portion of the coolant guide of the cooling circuit extends from the separation point to the power source. Power supply system according to one of Claims 9 to 17 wherein a portion of the coolant duct of the refrigeration cycle extends along the flow path from the power source to the energy sink. Power supply system according to one of Claims 9 to 18 wherein the cooling circuit has a control unit which is arranged in the supply unit or the consumer unit and which in particular automatically stops the charging process in the event of a fault. Power supply system according to one of Claims 9 to 19 , wherein the cooling circuit comprises a cooling unit, in particular an evaporator, for heat extraction from the cooling circuit. Power supply system according to one of Claims 9 to 20 , wherein the cooling circuit has a heat storage, in particular a latent heat storage. Power supply system according to one of Claims 9 to 21 wherein a motor vehicle forms the consumer unit and wherein the cooling circuit has a heat exchanger for heat dissipation to the motor vehicle. Power supply system according to one of Claims 9 to 22 wherein the cooling circuit comprises a sensor system, by means of which state information, in particular along the coolant guide, of the cooling circuit are detected. A supply line comprising a number of wires for transmitting electrical power, an integrated coolant guide for a coolant of a cooling circuit and having a formed by two complementary connector separation point, the two connectors have complementary electrical contacts for the transfer of electrical power and wherein the two connectors complement each other Have coolant connections for a coolant transfer. Supply line to Claim 24 designed for a power supply system according to one of the preceding claims. Supply line to Claim 24 or Claim 25 comprising at least one integrated signal line for the transmission of information signals, wherein the two connectors have contacts, in particular electrical contacts, for the transfer of information signals. A connection cable having a plurality of wires for transmitting electrical power, an integrated coolant guide for a coolant of a cooling circuit and a connector, wherein the connector has electrical contacts for the transfer of electrical power and wherein the connector has at least one coolant connection for a coolant transfer. Connecting cable after Claim 27 designed for a power supply system according to one of the preceding claims. Connecting cable after Claim 27 or Claim 28 comprising at least one integrated signal line for the transmission of information signals, the connector having contacts, in particular electrical contacts, for the transfer of information signals.

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