DE102017128963B4 - HIGH-VOLTAGE MELT FUSES AND POWER DISTRIBUTORS WITH HIGH-VOLTAGE MELT FUSES AND METHOD FOR THE PRODUCTION AND ASSEMBLY OF SUCH MELT FUSES - Google Patents

Abstract

High-voltage fuse (100) for use in a vehicle with
an electrically insulating housing (108),
a first contact element (102), from which a first end section (112) protrudes from the housing (108) on a first housing side (110),
a second contact element (104), from which a second end section (116) protrudes from the housing (108) on a second housing side (114) deviating from the first housing side (110),
wherein the first and second contact elements (102, 104) are electrically connected to one another by a fusible conductor (106) accommodated in the housing (108),
a first diagnostic contact element (118) coupled to the first contact element (102), of which a first diagnostic contact end section (122) is arranged substantially transversely to the first contact element (102),
a second diagnostic contact element (120) coupled to the second contact element (104), of which a second diagnostic contact end section (124) is arranged essentially transversely to the second contact element (104),
- Wherein the contact elements (102, 104) and the fusible conductor (106) and the first diagnostic contact element (118) and / or the second diagnostic contact element (120) consist of one piece of locking plate,
wherein the two contact elements (102, 104) folded at least two layers and the first diagnostic contact element (118) and / or the second diagnostic contact element (120) are formed in one layer and are formed as a stamped and bent part,
- And the first Diagnosekontaktendabschnitt (122) and / or the second Diagnosekontaktendabschnitt (124) are arranged in a plane transverse to a plane spanned by the contact elements (102, 104) plane.

Description

Technical area

The present invention relates to a high-voltage fuse for a motor vehicle and a power distributor with at least one such fuse and a manufacturing method and method of assembly of such a fuse.

State of the art

Fuses are used in many electrical and electronic devices to protect the user and components or lines of the device. In modern motor vehicles, for example, a large number of fuses can be found in order to electrically fuse individual supply paths or cable strands or loads. To facilitate the replacement of tripped fuses, these are often designed as plug-in fuse.

DE 10 2010 046 642 A1 discloses an electrical energy storage device comprising an electrical cell electrically connected to an electrical element via a conductor element. The conductor element has a securing element and is designed in particular as a stamped and bent element. As a result, an internal protection of the individual cells of the accumulator is preferably achieved.

DE 20 2009 002 852 U1 shows a fuse arrangement in particular for a motor vehicle electrical system, with a locking plate with a number of fuse elements designed as fuses to secure a respective current path, wherein the fuse elements voltage measuring outputs are provided with an evaluation unit for determining the current flowing over the respective current path electrical Stromes are connectable.

DE 10 2006 024 391 A1 describes a fuse unit with multiple plug especially for use in motor vehicles. The fuse unit comprises an electrically conductive busbar as a power supply and a plurality of terminals for individual consumers, which are electrically connected directly or via interposed fuses with the busbar. The bus bar has a contact tongue, which is designed to be brought into direct contact with an external potential as a plug geometry without the interposition of a further connection contour.

Also the JP 2010-015 715 A shows a fuse.

For a reliable operation of the motor vehicle or subsystems of the motor vehicle diagnostic functions on the state of the fuses used are useful or necessary. Currently, this is elaborately integrated either in ECUs, whereby system-specific no individual security statement can be made, or voltage taps are integrated into the screw connection of the screw-on. This results in both production and assembly, an additional expense.

Description of the invention

It is therefore an object of the invention to make it possible to perform a diagnostic function at the security level using structurally simplest possible means.

The object is solved by the subject matters of the independent claims. Advantageous developments of the invention are specified in the dependent claims, the description and the accompanying figures.

A fuse, which is provided in particular for use in a high-voltage electrical system in a vehicle, has a first contact element and a second contact element, which are electrically connected to each other by a fusible link. Furthermore, the fuse has an electrically insulating housing. The housing encloses the fusible conductor and in each case a partial section of the two contact elements. From the first contact element protrudes a first end portion on a first side of the housing out of the housing. From the second contact element protrudes a second end portion on a second housing side different from the first housing side out of the housing. The two contact elements penetrate thus each one of the sides of the housing. The walls of the housing are electrically insulated. At the first contact element, a first diagnostic contact element is formed. The first diagnostic contact element is arranged in a tolerance range transversely to the first contact element. The first diagnostic contact element can be oriented transversely either to the longitudinal extension of the first contact element and additionally or alternatively to the width extension of the first contact element.

A vehicle may, in particular, be understood to mean a motor vehicle which has a high-voltage vehicle electrical system with a voltage of more than 60 V. For example, the high-voltage electrical system of the motor vehicle may have a voltage of more than 400 V or more than 800 V.

In one embodiment, the housing is substantially cuboid. In an alternative embodiment, the housing has a substantially roll-cylindrical shape.

The fuse has a second diagnostic contact element coupled to the second contact element. A second diagnostic contact end portion of the second diagnostic contact element may be arranged substantially transversely to the second contact element.

The two contact elements and the first diagnostic contact element can be arranged in one plane. Furthermore, the first diagnosis contact element and the second diagnosis contact element can be arranged in one plane. In one embodiment, the two contact elements and the two diagnostic contact elements are arranged in one plane.

The first diagnostic contact end section is arranged in a plane transverse to a plane spanned by the two contact elements. The second diagnostic contact end section can be arranged in a plane transverse to a plane spanned by the two contact elements. Thus, the two diagnostic contact end sections can be arranged in a plane transverse to a plane spanned by the two contact elements. When at least one diagnostic contact end portion is disposed across the contact elements, a diagnostic contact element includes at least a diagnostic contact end portion and a diagnostic contact connection portion. The diagnostic contact connection portion connects the diagnosis contact end portion with the associated contact element.

The diagnostic contact end sections may be formed as blade contacts. The end portions of the two contact elements may be formed as blade contacts or as a mounting plate. A screw tab differs from a blade contact at least in a recess, for example, as a hole or round or oval recess made, which is suitable for a screw fastening.

The fusible conductor, the two contact elements and the first diagnostic contact element and, in addition or alternatively, the second diagnostic contact element are made in one piece from locking plate. In this case, the securing plate to increase the current carrying capacity in the region of the contact elements and the fusible conductor formed at least two layers and simultaneously formed the first diagnostic contact element and additionally or alternatively the second diagnostic contact element in one layer. Thus, the locking plate can be folded to produce the two-ply. It is inexpensive to produce the fuse as a stamped and bent part.

A variant of a fuse described here is used in a power distributor, a fuse box or a switch box, which are intended for use in a vehicle, to secure a supply path.

A method of manufacturing a fuse for use in a vehicle includes at least a step of forming and a step of arranging. The order of the two steps can be chosen arbitrarily. In the step of forming, a first contact element, a second contact element and a fuse element which electrically connects the two contact elements to one another are formed. Furthermore, a first diagnosis contact element which is coupled to the first contact element and which is arranged substantially transversely to the contact element is formed. In the arranging step, an electrically insulating housing is arranged such that a first end section of the first contact element projects out of the housing on a first housing side and a second end section of the second contact element projects out of the housing on a second housing side that is different from the first housing side.

In a particular embodiment, the first housing side is opposite to the second housing side.

In one embodiment, the elements or features formed in the step of forming are formed from a securing plate, in particular in a stamping and bending process.

A method of assembling a fuse in a power distributor for use in a vehicle includes a step of providing, a step of placing, a step of contacting, and another step of contacting. In the step of providing a variant of a fuse described here is provided. In the arranging step, the fuse is arranged on a busbar such that the first contact element of the fuse is in contact with the busbar. In the subsequent contacting step, the first contact element is electrically and mechanically connected to the busbar by means of a connection method such as, for example, inserting, plugging or bonding. In the subsequent step of contacting, the first diagnostic contact element is contacted by means of a plug connection.

list of figures

• 1 eine vereinfachte Darstellung einer Schmelzsicherung im Schnitt gemäß einem Ausführungsbeispiel der vorliegenden Erfindung;
• 2 eine isometrische Darstellung einer Schmelzsicherung nach 1 gemäß einem Ausführungsbeispiel der vorliegenden Erfindung;
• 3 und 4 eine Seitenansicht einer Schmelzsicherung gemäß einem Ausführungsbeispiel der vorliegenden Erfindung;
• 5 und 6 eine isometrische Detail-Darstellung einer in 2 bis 4 gezeigten Schmelzsicherung gemäß einem Ausführungsbeispiel der vorliegenden Erfindung;
• 7 ein Fahrzeug mit einem Stromverteiler mit zumindest einer Schmelzsicherung gemäß einem Ausführungsbeispiel der vorliegenden Erfindung;
• 8 einen Ablaufplan eines Verfahrens zum Herstellen einer Schmelzsicherung zum Einsatz in einem Fahrzeug gemäß einem Ausführungsbeispiel der vorliegenden Erfindung; und
• 9 einen Ablaufplan eines Verfahrens zur Montage einer Schmelzsicherung in einem Stromverteiler zum Einsatz in einem Fahrzeug gemäß einem Ausführungsbeispiel der vorliegenden Erfindung.

Hereinafter, an advantageous embodiment of the invention will be explained with reference to the accompanying figures. Show it:

• 1 a simplified representation of a fuse in section according to an embodiment of the present invention;
• 2 an isometric view of a fuse after 1 according to an embodiment of the present invention;
• 3 and 4 a side view of a fuse according to an embodiment of the present invention;
• 5 and 6 an isometric detail representation of an in 2 to 4 shown fuse according to an embodiment of the present invention;
• 7 a vehicle having a power distributor with at least one fuse according to an embodiment of the present invention;
• 8th a flowchart of a method of manufacturing a fuse for use in a vehicle according to an embodiment of the present invention; and
• 9 a flowchart of a method for mounting a fuse in a power distribution for use in a vehicle according to an embodiment of the present invention.

The figures are merely schematic representations and serve only to illustrate the invention. Identical or equivalent elements are consistently provided with the same reference numerals.

In functionally critical subnetworks of the vehicle electrical system, the secure supply of consumers is to be achieved by a diagnosis of fuses. The supply of the affected consumers of the subnet is carried out via conventional fuses whose triggering is monitored or diagnosed.

1 shows a fuse 100 , The fuse 100 has a first contact element 102 and a second contact element 104 on, which by means of a fusible conductor 106 connected to each other. Furthermore, the fuse comprises 100 an electrically insulating housing 108 , From the first contact element 102 protrudes on a first side of the housing 110 a first end section 112 of the first contact element 102 out of the case 108 out. From the second contact element 104 protrudes on a second side of the housing 114 a second end section 116 of the second contact element 104 out of the case 108 out. Here are the two sides of the housing 110 . 114 different from each other. In the in 1 embodiment shown are the two sides of the housing 110 . 114 on two opposite sides of the housing 108 arranged. The contact elements 102 . 104 each penetrate a housing wall, so that a portion of the contact elements 102 . 104 inside the case 108 and another as an end section 112 . 116 designated subsection of the contact elements 102 . 104 outside the case 108 is arranged.

At the two contact elements 102 . 104 each is a diagnostic contact element 118 . 120 arranged. This is the case at the first contact element 102 a first diagnostic contact element 118 arranged and electrically coupled with this. On the second contact element 104 is a second diagnostic contact element 120 arranged and electrically coupled with this. The two diagnostic contact elements 118 . 120 are essentially transverse to the two contact elements 102 . 104 arranged. In the in 1 illustrated embodiment, the two diagnostic contact elements 118 . 120 essentially transversely to the longitudinal extent of the contact elements 102 . 104 arranged. In an alternative embodiment, such as in 2 are each a diagnostic contact end section 122 . 124 the two diagnostic contact elements 118 . 120 essentially transversely to one through the two contact elements 102 . 104 aligned plane. So have the diagnostic contact elements 118 . 120 each a diagnostic contact connection portion 126 . 128 on. A first diagnostic contact connection section 126 connects the first diagnostic contact end section 122 with the associated first contact element 102 , A second diagnostic contact connection section 128 connects the second diagnostic contact end section 124 with the associated second contact element 104 ,

In the in 1 illustrated embodiment, the two contact elements 102 . 104 shaped as a screw-on. For this purpose, the two contact elements 102 . 104 one recess each 130 on. The recess 130 is as a circular breakthrough in each end section 112 . 114 formed. So it may be at the recess 130 for example, to act a hole.

As can be seen more clearly from the following figures, the fuse shown here is 100 to a high-voltage fuse. For condition detection of the fuse 100 are at both contact zones, ie at the two contact elements 102 . 104 or in the vicinity, electrical taps required.

If, as in the present embodiment, for reasons of electrical power, the contact elements 102 . 104 be screwed, it is customary in the known state of the art to integrate corresponding voltage taps for the state detection on the screw-on of the fuse in the screw. Alternatively, separate to bolt in an adjacent busbar are known. The disadvantage, however, is then to consider a particular assembly order. By the additional diagnostic contact elements described here 118 . 120 can a manufacturing advantage be achieved because of a simple connector over the fuse 100 tapped current flowing and thus the state of the fuse can be determined. Thus, an optimization of the production is achieved by defined contact tongues as voltage taps on both sides of the fuse. Advantageously, a defined contacting with a defined contact resistance is made possible. Furthermore, thereby increase the degrees of freedom in terms of mounting order.

2 shows a further embodiment of a fuse 100 in a perspective oblique view. In this embodiment, the two diagnostic contact end portions 122 . 124 in a plane transverse to one of the contact elements 102 . 104 arranged spanned plane. The two diagnostic contact connection sections 126 . 128 have an approximately 90 ° bend and provide both mechanical and electrical coupling between the associated contact element 102 . 104 and the respective diagnostic contact end portion 122 . 124 , The housing 108 has a circular cylindrical shape. The two cutting circle surfaces of the circular cylinder form the first side of the housing 110 as well as the second housing side 114 , from each of which one of the two contact elements 102 . 104 out of the case 102 protrudes.

The two contact elements 102 . 104 connecting fusible link 106 is not explicitly shown, it is from the housing 108 enclosed.

Both at the in 1 shown embodiment as well as in the 2 embodiment shown are in a preferred variant, the two contact elements 102 . 104 , the two diagnostic contact elements 118 . 120 , as well as the fusible link 106 manufactured in one piece from a locking plate. Here, in a particularly preferred embodiment, the contact elements 102 . 104 double-layered and the two diagnostic contact elements 118 . 120 single-layered. In this case, the locking plate can be folded after a punching operation in the region of the contact elements, wherein the diagnostic contact elements 118 . 120 forming flag of the locking plate only on one of the two contact elements 102 . 104 forming layers is formed. This is off 4 to 6 even clearer.

3 to 6 show that in 2 shown embodiment in different views. 3 shows a side view, 4 shows a further side view on the front side, 5 also shows a front page in detail view and 6 shows the in 5 shown front side in a rotated detail view. Especially in the detail views in 5 and 6 is the two-layer formation of the contact elements 102 . 104 by folding the securing plate and the first diagnosis contact element formed on a position of the securing plate 118 seen.

7 shows a vehicle 740 , The vehicle 740 has a power distributor 742 on, in which at least one fuse 100 and a power rail 744 are arranged. One of the two contact elements 102 . 104 is with the busbar 744 screwed. The fuse 100 is set up, a supply path 746 over a line 748 from an energy store 750 to a load 752 secure. The two diagnostic contact elements 118 . 120 the fuse are via connectors with a monitoring device 754 for condition monitoring of the fuse 100 connected.

The power distributor 742 here stands representative for switch boxes or fuse boxes in which fuses are used. The advantages of the solution shown here are especially in the high-voltage range greater than 400 V.

For ease of understanding, reference numerals will be used in the following description 1 - 7 retained as a reference.

8th shows a method for producing a fuse 100 for use in a vehicle 740 , The method comprises at least one step S1 training as well as a step S2 of arranging. In step S1 the formation becomes a first contact element 102 , a second contact element 104 , one the two contact elements 102 . 104 interconnected with each other fuse conductor 106 and one with the first contact element 102 coupled first diagnostic contact element 118 of which a first diagnostic contact end portion 122 substantially transverse to the first contact element 102 is arranged, formed. In step S2 arranging becomes an electrically insulating housing 108 arranged such that a first end portion 112 of the first contact element 102 on a first side of the housing 110 out of the case 108 protrudes as well as a second end portion 116 of the second contact element 104 on one of the first side of the housing 110 different second housing side 114 out of the case 108 protrudes.

In a particular embodiment of the in 8th shown method is in step S1 the formation of a locking plate provided and the two contact elements 102 . 104 , the fuse wire 106 and the first diagnostic contact element 118 and if present, the second diagnostic contact element 120 formed by punching from the locking plate. Thus, the said elements are produced as a one-piece stamped and bent part.

9 shows a method for mounting a fuse 100 in a power distributor 742 for use in a vehicle 700 , The method comprises four steps S3 to S6 , In step S3 the provision of at least one fuse 100 a variant of an in 1 to 7 shown fuse 100 provided. In step S4 arranging becomes the at least one fuse 100 on a power rail 744 arranged so that one of the two contact elements 102 . 104 with the busbar 744 is in contact. In step S5 the contacting becomes the first contact element 102 with the busbar 744 electrically and mechanically firmly coupled. In a final step S6 the contacting becomes the first diagnosis contact element 118 contacted by means of a plug connection. In a preferred embodiment, the fuse 100 a second diagnostic contact element 120 on, which is also contacted by means of a plug connection. The connector allows a monitoring device 754 a condition monitoring of the fuse via the established for a voltage tap diagnostic contact elements 118 . 120 ,

The fuse described here on an embodiment 100 is easy to integrate in power distributors and fuse boxes. Advantageously, there is a very favorable cost structure over fully electronic solutions, since the concept is based on today already in use technology and components.

LIST OF REFERENCE NUMBERS

100

fuse

102

first contact element

104

second contact element

106

fuse element

108

casing

110

first housing side

112

first end section

114

second side of the housing

116

second end section

118

first diagnostic contact element

120

second diagnostic contact element

122

first diagnostic end portion, first diagnostic contact end portion

124

second diagnostic end section, second diagnostic contact end section

126

first diagnostic contact connection portion

128

second diagnostic contact connection portion

130

recess

740

vehicle

742

power distribution

744

conductor rail

746

supply route

748

management

750

Energy storage, battery

752

Load, consumer

754

Monitoring device, control unit

S1 - S6

steps

Claims (5)

High-voltage fuse (100) for use in a vehicle with - an electrically insulating housing (108), - a first contact element (102), of which a first end portion (112) on a first side of the housing (110) from the housing (108 a second contact element (104), from which a second end section (116) protrudes from the housing (108) on a second housing side (114) deviating from the first housing side (110), the first and second contact elements (104) 102, 104) are electrically connected together by a fusible conductor (106) received in the housing (108), - a first diagnostic contact element (118) coupled to the first contact element (102), of which a first diagnostic contact end section (122) is substantially transverse to first contact element (102) is arranged, - a second diagnostic contact element (120) coupled to the second contact element (104), of which a second diagnostic contact end section (124) is arranged substantially transversely to the second contact element (104), - wherein the contact elements (102, 104) and the fusible conductor (106) and the first diagnostic contact element (118) and / or the second diagnostic contact element (120) consist of one piece of locking plate - wherein the two contact elements (102, 104) folded at least two layers and the first diagnostic contact element (118) and / or the second diagnostic contact element (120) are formed in one layer and formed as a stamped and bent part, - and the first Diagnosekontaktendabschnitt (122) and / or the second diagnostic contact end portion (124) is disposed in a plane transverse to a plane defined by the contact elements (102, 104). High-voltage fuse (100) after Claim 1 , characterized in that the two contact elements (102, 104) and / or the two diagnostic contact elements (118, 120) are designed as blade contacts and / or are formed as a mounting plate with a recess (130) for a Sch raubbefestig ung. Power distributor (742) for use in a vehicle with at least one high-voltage fuse (100) according to one of the preceding claims. Method for producing a high-voltage fuse (100) for use in a vehicle, comprising the following steps: Forming a first contact element (102), a second contact element (104), and a fuse conductor (106) electrically interconnecting the two contact elements (102, 104) and a first diagnostic contact element (118) coupled to the first contact element (102) of which a first diagnostic contact end portion (122) is disposed substantially transverse to the first contact element (102) and to a second diagnostic contact element (120) coupled to the second contact element (104), of which a second diagnostic contact end portion (124) is substantially transverse to the second Contact element (104) is arranged, wherein in the step of forming a locking plate is provided and the first contact element (102), the second contact element (104), the fusible conductor (106), the first diagnostic contact element (118) and / or the second diagnostic contact element ( 120) are formed by punching from the locking plate, Folding the two contact elements (102, 104) at least in two layers, Bending the first diagnostic contact end section (122) and / or the second diagnostic contact end section (124) so that they are arranged in a plane transverse to a plane spanned by the contact elements (102, 104), and Arranging an electrically insulating housing (108) such that a first end section (112) of the first contact element (102) protrudes from the housing (108) on a first housing side (110), and a second end section (116) of the second contact element (104 ) protrudes from the housing (108) on a second housing side (114) which is different from the first housing side (110). A method for assembling a high-voltage fuse (100) in a power distributor (742) for use in a vehicle, comprising the steps of: - providing at least one high-voltage fuse (100) according to one of Claims 1 to 2 and a busbar (744), - arranging the high-voltage fuse (100) on the busbar, so that the first contact element (102) in contact with the busbar (744), - contacting the first contact element (102) by means of screws, clinching, plugging or bonding to the bus bar (744), and - contacting the first diagnostic contact element (118) by means of a plug connection.

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