DE102017211686A1 - Charging module for a vehicle - Google Patents

Abstract

A charging module (125) for a vehicle (120) is described. The charging module (125) comprises a first partial charging device (210) for providing a first DC partial charging current, wherein a first AC main terminal (212), a first auxiliary AC terminal (214) is connected to the first housing (211) of the first submodule (210) ) and a first DC main terminal (213) are arranged. The first AC main terminal (212) is connected to the first auxiliary AC terminal (214) via an internal AC line (216). In addition, the charging module (125) comprises a second partial charger (220) for providing a second DC partial charging current, wherein a second AC main terminal (222) and a second DC main terminal (222) are attached to the second housing (221) of the second partial charger (120). 223) are arranged. The first auxiliary AC terminal (214) is connected to the second main AC terminal (222) via an external AC line (203) for supplying a portion of an AC charging current to the first and second sub-charging units (210, 220), respectively. In addition, the charging module (125) includes means for providing a DC charging current based on the first and second partial charging currents.

Description

The invention relates to an AC charging module for an at least partially electrically powered vehicle.

Electric vehicles (especially electric vehicles or plug-in hybrid vehicles) include electrical energy stores (e.g., batteries) that may be charged via a charging device or via a charging module (the vehicle or a charging station). To charge the electrical energy stores of such electric and / or hybrid vehicles, there are various conductive, i. Wired and / or inductive charging technologies. The charging process of an electrical energy storage device typically takes a relatively long time.

In the so-called AC charging or AC charging is the charging module, which converts the DC power (also referred to as DC power) for charging the electrical storage in the vehicle. An alternating current (AC) or alternating current is transmitted on a charging cable between the charging station and the vehicle. For example, the energy storage can be charged especially when charging in a private household at 16A with up to 3.7kW or 32A with up to 7.4kW. By increasing the charging power, a charging process can be accelerated.

The present document deals with the technical task of providing a cost, weight and space efficient charging module for providing flexibly scalable charging power.

The object is solved by the independent claims. Advantageous embodiments are described i.a. in the dependent claims. It should be noted that additional features of a claim dependent on an independent claim without the features of the independent claim or only in combination with a subset of the features of the independent claim may form an independent invention independent of the combination of all features of the independent claim, the subject of an independent claim, a divisional application or a subsequent application. This applies equally to technical teachings described in the specification, which may form an independent invention of the features of the independent claims.

In one aspect, a charging module for providing a DC charging current for charging an electrical energy store (e.g., a lithium ion battery) of a vehicle (particularly a road vehicle) is described. The charging module may be installed in a vehicle to provide an alternating current (AC) charging current, e.g. to transfer a charging current at a 230V AC voltage into a DC (direct current) charging current. The charging module may be configured to provide a charging current of 32A or more and / or a charging power of 7.4kW or more.

The charging module includes a first part charger having a first housing, the first housing enclosing a first rectifier or converter for providing a first DC part charging current. The first rectifier may e.g. a switching power supply include. The first rectifier may convert a first AC partial charging current at the input of the first rectifier into the first DC partial charging current. In this case, the first rectifier can be completely enclosed by the first housing. The first housing may comprise an electrically conductive material, in particular a metal, or consist of such a material. The first housing can thus be used to shield electromagnetic radiation. The first sub-charger and in particular the first rectifier may be configured to provide a partial charging current of 16A or more and / or a charging power of 3.7kW or more.

At least a first AC main terminal, a first AC auxiliary terminal, and a first DC main terminal are disposed on the first housing. The individual terminals may each be designed as interface elements of a plug connection (i.e., as plugs or sockets).

The first AC main terminal is electrically conductively connected to the input of the first rectifier (possibly directly via a housing-internal line) to supply an AC charging current at the AC main terminal at least partially from the first AC main terminal to the input of the first Rectifier lead. In particular, a first AC partial charging current can be brought to the input of the first rectifier.

Further, the first AC main terminal is connected to the first auxiliary AC terminal via an internal (AC) line (electrically conductive) to supply the AC main current to the main AC terminal at least partially from the first main AC terminal to the first auxiliary AC terminal first AC auxiliary connection. In particular, a second AC partial charging current can be conducted to the first auxiliary AC connection. By providing an auxiliary AC terminal to the first housing of the first sub-charger, at least a portion of the AC charging current provided to a vehicle's charging socket can be efficiently isolated (particularly without the use of a dedicated AC side) Power distributor) are forwarded to at least one further partial charger.

The first DC main terminal is connected to the output of the first rectifier to provide the first DC partial charging current.

In addition, the charging module comprises a second sub-charger with a second housing, the second housing enclosing a second rectifier or converter for providing a second DC partial charging current (typically completely). The second sub-charger may be constructed (apart from one or more internal lines and / or terminals) corresponding to and / or the same as the first sub-charger.

At least a second AC main terminal and a second DC main terminal may be arranged on the second housing of the second partial charger. In this case, the second AC main terminal (via a housing-internal line, electrically conductive) is connected to the input of the second rectifier to direct an AC partial charging current to the second rectifier. In addition, the second DC main terminal is connected to the output of the second rectifier to provide the second DC partial charging current to the second DC main terminal.

The first AC auxiliary terminal may be connected to the second main AC terminal via an (external) AC line, so that each of the first and second rectifiers has a part of an AC charging current (eg, a first AC partial charging current) second AC partial charging current) can be supplied. In addition, the charging module includes means (e.g., a DC side power distributor) for providing a DC charging current for charging an energy storage based on the first and second partial charging currents.

By using and linking terminals of a partial charger described in this document can be dispensed with the use of at least one power distribution, so that a cost, space and weight-efficient charging module can be provided for a vehicle.

A second DC auxiliary connection can be arranged on the second housing of the second partial charger, wherein the second DC main connection can be electrically conductively connected to the second DC auxiliary connection via a (housing) internal DC line. The first DC main terminal of the first partial load module may then be connected to the second DC auxiliary terminal via a (housing) external DC line to provide the DC charging current to the second DC main terminal based on the first and second partial charging currents. As a result, it is also possible to dispense with a power distributor on the DC side, so that costs, installation space and weight of the charging module can be further reduced.

The first sub-charger and / or the second sub-charger may each include one or more additional DC auxiliary terminals configured to be connected to a DC charging source and / or to a DC consumer. Thus, the wiring can be optimized in a vehicle and thus weight, cost and space can be reduced.

The first AC main terminal (on the first housing of the first divadder module) may be configured to be electrically conductively coupled to a vehicle's charging socket to provide an AC charging current to the first AC main terminal that is divided into two or more AC terminals. Partial load currents can be divided.

The second DC main terminal (on the second housing of the second divisional module) may be configured to be coupled to the energy storage of a vehicle to provide DC power to the second DC main terminal based on the two or more DC partial charge currents of the two or more sub-chargers. To provide (total) charging current for charging the energy storage.

The loading module may include one or more intermediate part chargers, wherein the one or more intermediate part chargers may be disposed between the first part charging device and the second part charging device. An intermediate component charger can be constructed in accordance with or structurally identical to the first and / or second partial charger (apart from one or more internal lines and / or connections).

In particular, an intermediate charger may include a housing enclosing a rectifier for providing a DC partial charging current. At least one of an AC main terminal, an AC auxiliary terminal, a DC main terminal, and a DC auxiliary terminal may be disposed on the housing of the sub-component charger. An intermediate component charger may thus correspond to a combination of the first part charger and the second part charger with respect to the terminals and the internal leads.

The AC The main connection of the intermediate component charger can be connected to the input of the rectifier of the intermediate component (electrically conductive) (eg via a housing-internal line). The AC Main Connection of the Intermediate Battery Charger can be connected to the AC auxiliary connection of the Inter-Particle Charger (electrically conductive) via an (internal) AC line. The DC main connection of the intermediate component charger may be connected to the output of the rectifier of the intermediate component charger (electrically conductive) (eg via a housing-internal line). In addition, the DC main connection of the intermediate component charger can be connected via a (housing) internal DC line to the DC auxiliary connection of the intermediate component charger (electrically conductive).

The AC main connection of an intermediate component charger can then be connected via an (external) AC line to the AC auxiliary connection of the first part charger (electrically conductive). If necessary, the connection can be made indirectly via the AC auxiliary connections and the AC main connections of one or more other intermediate part chargers.

The DC main connection of an intermediate component charger can be connected via a (housing) external DC line to the DC auxiliary connection of the second part charger (electrically conductive). If necessary, the connection can be made indirectly via the DC auxiliary connections and the DC main connections of one or more other intermediate part chargers.

By providing one or more intermediate part chargers, the charging power of the charging module can be increased stepwise (in terms of space, cost and weight) (by the charging power of the individual part chargers).

According to a further aspect, a charging module for providing a DC charging current for charging an energy store of a vehicle is described. The design in this document with respect to a loading module apply in a corresponding, in particular in the same way, for this loading module.

The charging module includes a first sub-charger having a first housing enclosing a first rectifier for providing a first DC partial charging current. At least a first AC main terminal and a first DC main terminal are arranged on the first housing. The first AC main terminal is connected to the input of the first rectifier (electrically conductive) (e.g., via a housing internal lead). The first DC main terminal is connected to the output of the first rectifier (electrically conductive) (e.g., via a housing-internal line).

In addition, the charging module comprises a second sub-charger with a second housing enclosing a second rectifier for providing a second DC partial charging current. At least a second AC main terminal, a second DC auxiliary terminal and a second DC main terminal are arranged on the second housing. The second AC main terminal is connected to the input of the second rectifier (electrically conductive) (e.g., via a housing internal lead). The second DC main terminal is connected to the output of the second rectifier (electrically conductive) (e.g., via a housing-internal line). In addition, the second DC main terminal is connected to the second DC auxiliary terminal through a (housing) internal DC line (electrically conductive).

The first DC main terminal is connected to the second DC auxiliary terminal through an external DC line to provide a DC charging current to the second DC main terminal based on the first and second partial charging currents. It can thus be dispensed with a DC-side power distributor, so that a space-saving, weight and cost-efficient charging module is provided.

In addition, the charging module includes means (e.g., an AC side power distributor) for supplying a portion (e.g., equal parts, respectively) of an AC charging current to each of the first and second rectifiers. For this purpose, a first AC auxiliary connection is preferably arranged on the first housing of the first partial charger, wherein the first AC main connection is connected to the first auxiliary AC connection via an (internal) AC line (electrically conductive). The first AC auxiliary terminal may be connected to the second AC main terminal via an external AC line to supply each of the first and second rectifiers with a part of the AC charging current. Thus, on the AC side can be dispensed with a power distribution, so that space, cost and weight of the load module can be further reduced.

In another aspect, a road vehicle (particularly a passenger car or a truck or a bus or a motorcycle) is described that includes the charging module described in this document. In particular, the vehicle may comprise an electrical energy store and a charging socket, wherein the charging socket is set up to be connected to a charging station via a charging cable. The charging module may be configured to provide a DC charging current for charging the energy storage based on an AC charging current provided at the charging socket.

It should be understood that the devices and systems described herein may be used alone as well as in combination with other devices and systems described in this document. Furthermore, any aspects of the devices and systems described in this document may be combined in a variety of ways. In particular, the features of the claims can be combined in a variety of ways.

• 1a ein beispielhaftes System zum Laden eines Fahrzeugs;
• 1b beispielhafte Komponenten eines elektrischen HV-Bordnetzes eines Fahrzeugs; und
• 2a und 2b beispielhafte Lademodule mit mehreren Teilladegeräten.

Furthermore, the invention will be described in more detail with reference to exemplary embodiments. Show

• 1a an exemplary system for loading a vehicle;
• 1b exemplary components of an electrical HV vehicle electrical system of a vehicle; and
• 2a and 2 B exemplary charging modules with several part chargers.

As set forth above, the present document is concerned with the provision of a flexibly scalable charging module for a vehicle that can be used to provide different charging powers as needed. 1a shows in this context a block diagram of an exemplary charging system 100 with a charging station 110 and a vehicle 120 , The vehicle 120 includes an electrical energy storage 122 using electrical energy from the charging station 110 can be charged. The vehicle 120 includes a charging socket 121 at the appropriate plug 111 a charging cable 112 can be infected. The charging socket 121 and the plug 111 form a plug-in system. The charging cable 112 can firmly with the charging station 110 be connected (as shown). On the other hand, the charging cable 112 via a plug connection with the charging station 110 be connected (especially in AC charging).

The vehicle 120 includes a charging control unit 123 that is set up to charge at the charging station 110 to control. For this purpose, the charging control unit 123 of the vehicle 120 be set up with the charging station 110 to communicate according to a predefined communication protocol.

1b shows further details of a high voltage (HV) vehicle electrical system 120 , In the illustrated example, the vehicle includes 120 a charging module or a charger 125 with an AC / DC converter, wherein the AC / DC converter is arranged, an alternating current from the charging station 110 to convert into a direct current for the HV electrical system. In this case, the converter of the charging module 125 be set up a certain, constant DC to charge the electrical energy storage 122 provide. Alternatively or additionally, the converter of the charging module 125 be configured to provide a DC with a constant voltage. In other words, the converter of the charging module 125 can be regulated to a certain charging current and / or to a certain charging voltage. At the in 1b Example shown is an AC charging the electrical energy storage 122 because of the charging cable 112 an alternating current flows.

The charging module 125 is via lines 129 a vehicle electrical system 120 with the electrical energy storage 122 connected. At the charging module 125 and / or on the electrical system can other consumers 126 . 127 . 128 be connected. Exemplary consumers are: a DC / DC converter 126 for supplying a low-voltage (NV) on-board network of the vehicle 120 (especially one 12 / 14V Electrical system), an inverter 127 for generating a three-phase current for driving an electric drive machine of the vehicle 120 , a continuous flow heater for generating heat energy and / or a refrigerant compressor / a cooling unit 128 for cooling, in particular for cooling the electrical energy storage 122 , Furthermore (if necessary directly at the loading module 125 ) one or more further charge sources (eg a generator) to be electrically conductively connected to the electrical system, to electrical energy for the electrical system and / or for the energy storage 122 provide.

As in 2a shown, the loading module 125 of a vehicle 120 to increase the charging power several part chargers 210 . 220 include. This in 2a illustrated charging module 125 includes a first part charger 210 and a second part charger 220 , which have a charging socket-side (ie an AC-side) power distributor 201 and an energy storage side (ie, a DC side) power distribution 202 are arranged parallel to each other, each to a part of the total charging power for charging the energy storage 122 provide. The part chargers 210 . 220 For example, each 3.7kW charging power at each 16A deploy, leaving the loading module 125 a total charging power of 7.4kW 32A having.

The first part charger 210 includes a first housing 211 , in which a first AC / DC converter (short converter) or rectifier 215 is arranged. An AC input of the first converter 215 is via an enclosure-internal wiring with an AC main connection 212 on the first housing 211 coupled, and a DC output of the first converter 216 is via a housing-internal wiring with a DC main connection 213 on the first housing 211 coupled. The energy storage 122 of the vehicle 120 can with the DC main connection 213 be coupled (eg via lines 129 the electrical system of a vehicle 120 ). In addition, the first part charger includes 210 typically one or more auxiliary ports 214 on the first housing 211 for one or more consumers 126 . 127 . 128 and / or for one or more additional charge sources (eg, a generator) of the vehicle 120 , The one or more auxiliary connections 214 can connect via housing internal wiring to the DC output of the first converter 216 and / or with the DC main connection 213 be connected.

The second part charger 220 can be constructed in a corresponding manner, with a second housing 221 , with a second AC / DC converter 225 , with an AC main connection 222 , with a DC main connection 223 and with one or more auxiliary ports 224 , The AC main connection 222 Can via an external AC line 203 with the AC side power distributor 201 and the DC main terminal 223 can be over a DC line 204 with the DC side power distributor 202 be coupled.

In the 2a illustrated parallel arrangement of several part chargers 210 . 220 has several disadvantages: There are additional charging current distributor 201 . 202 used, which require additional space and cause additional weight. Typically, with multiple part chargers 210 . 220 not all auxiliary connections 213 . 223 the part chargers 210 . 220 be used so that one or more of the already existing auxiliary connections 213 . 223 have to be blinded and / or isolated (as through the auxiliary connection 224 in 2a illustrated). At an auxiliary connection 214 a partial charger 210 An additional charge source (eg an electric machine operated as a generator) may be connected. In case of failure of the part charger 210 The additional charge source connected to it typically also fails and can therefore no longer charge the energy store 122 contribute.

2 B shows a charging module 125 with several part chargers 210 . 220 , which makes it possible to avoid the above-mentioned disadvantages in whole or in part. The first part charger 210 includes a direct internal AC line 216 between the AC main terminal 212 and an auxiliary connection 214 , The auxiliary connection 214 thus becomes as an AC auxiliary connection 214 used. Via the internal AC line 216 Can the from the charging socket 121 incoming AC charging current at least partially directly from the AC main terminal 212 of the first part charger 210 to the AC auxiliary connection 214 of the first part charger 210 to get redirected. The AC auxiliary connection 214 of the first part charger 210 can then have an external AC line 203 with the AC main connection 222 of the second part charger 210 be coupled.

The second part charger 220 includes an internal DC line 226 between an auxiliary terminal used as a DC auxiliary terminal 224 and the DC main connector 223 , This internal DC line 226 is preferred for that of the first part charger 210 provided DC charging power designed. The DC main connection 213 of the first sub-charger 210 can then via an external DC line 204 with the DC auxiliary connection 224 of the second part charger 220 be coupled.

The AC voltage input 222 of the second part charger 220 can thus be connected to an AC auxiliary connection 214 for the additional charge of the first part charger 210 be connected. Thus, the shares of the charging socket 121 incoming AC input current from 32A (Ampere) within the first part charger 210 on each 16A per rectifier or AC / DC converter 215 . 225 on. The rectified voltage and / or the rectified current of the first part charger 210 can via a DC auxiliary connection 224 for extra charge the second part charger 220 can be supplied and thus unhindered in the energy storage 122 of the vehicle 120 flow. The determination of the pin assignments of the auxiliary connections 214 . 224 the part chargers 210 . 220 can be at least partially by an electrical control unit 123 of the vehicle 120 be effected.

Thus, a space-, cost- and weight-efficient, scalable load module 125 to be provided. It can be several substantially identical partial chargers 210 . 220 be used.

The present invention is not limited to the embodiments shown. In particular, it should be noted that the description and figures are intended to illustrate only the principle of the proposed methods, apparatus and systems.

Claims (10)

Charging module (125) for a vehicle (120); the charging module (125) comprising a first part charger (210) having a first housing (211) enclosing a first rectifier (215) for providing a first DC part charging current; wherein at least a first AC main terminal (212), a first AC auxiliary terminal (214) and a first DC main terminal (213) are disposed on the first housing (211); wherein the first AC main terminal (212) is connected to an input of the first rectifier (215) and to the first auxiliary AC terminal (214) via an internal AC line (216); wherein the first DC main terminal (213) is connected to an output of the first rectifier (215); and - a second partial charger (220) having a second housing (221) enclosing a second rectifier (225) for providing a second DC partial charging current; wherein at least a second AC main terminal (222) and a second DC main terminal (223) are arranged on the second housing (221); wherein the second AC main terminal (222) is connected to an input of the second rectifier (225) is connected; wherein the second DC main terminal (213) is connected to an output of the second rectifier (225); wherein the first AC auxiliary terminal (214) is connected to the second AC main terminal (222) via an external AC line (203) to supply each of the first and second rectifiers (215, 225) with a part of an AC charging current ; and wherein the charging module (125) includes means for providing a DC charging current based on the first and second partial charging currents. Charging module (125) according to Claim 1 wherein a second DC auxiliary terminal (224) is disposed on the second housing (221) of the second sub-charger (220); the second DC main terminal (213) is connected to the second DC auxiliary terminal (223) via an internal DC line (226); and - the first DC main terminal (213) is connected to the second DC auxiliary terminal (223) via an external DC line (204) to connect the DC to the second DC main terminal (223) based on the first and second partial charging currents Charge to provide. The charging module (125) according to one of the preceding claims, wherein the first partial charger (210) and / or the second partial charger (220) comprise one or more further DC auxiliary terminals (224) arranged with a DC charge source and / or to be connected to a DC consumer (126, 127, 128). Loading module (125) according to one of the preceding claims, wherein - the first part charger (210) and / or the second part charger (220) are arranged to provide respectively a partial charge current of 16A or more and / or each a charge power of 3.7kW or more; and - The charging module (125) is arranged to provide a charging current of 32A or more and / or a charging power of 7.4kW or more. Charging module (125) according to one of the preceding claims, wherein the first and / or second rectifier (215, 225) each comprise a switching power supply. Loading module (125) according to one of the preceding claims, wherein - The first AC main terminal (212) is adapted to be coupled to a charging socket (121) of a vehicle (120); and - The second DC main terminal (223) is adapted to be coupled to the energy storage (122) of a vehicle (120). Loading module (125) according to one of Claims 2 to 6 in which - the loading module (125) comprises one or more intermediate part chargers; - An intermediate charger comprises a housing enclosing a rectifier for providing a DC partial charging current; - On the housing of an intermediate part charger at least one AC main terminal, an AC auxiliary terminal, a DC main terminal and a DC auxiliary terminal are arranged; - the main AC terminal of an intermediate component is connected to an input of the rectifier of the intermediate component; - the AC main connection of an intermediate component is connected via an internal AC line to the AC auxiliary connection of the intermediate part loader; - the DC main terminal of an intermediate part charger is connected to an output of the rectifier of the intermediate part loader; - the DC main connection of an intermediate component charger is connected to the DC auxiliary connection of the intermediate component charger via an internal DC line; - the AC main terminal of an intermediate part charger is connected to the AC auxiliary terminal (214) of the first part loader (210) via an external AC line; and - the DC main terminal of an intermediate part charger is connected to the DC auxiliary terminal (224) of the second part charger (220) via an external DC line. Loading module (125) according to one of the preceding claims, wherein - The housing (211, 221) of a part charger (210, 220), the rectifier (215, 225) of the Teilladegeräts (210, 220) completely encloses; and or - The housing (211, 221) of a part charger (210, 220) an electrically conductive material, in particular a metal comprises. Charging module (125) for a vehicle (120); the charging module (125) comprising a first part charger (210) having a first housing (211) enclosing a first rectifier (215) for providing a first DC part charging current; wherein at least a first AC main terminal (212) and a first DC main terminal (213) are disposed on the first housing (211); wherein the first AC main terminal (212) is connected to an input of the first rectifier (215); wherein the first DC main terminal (213) is connected to an output of the first rectifier (215); and - a second partial charger (220) having a second housing (221) enclosing a second rectifier (225) for providing a second DC partial charging current; wherein at least a second AC main terminal (222), a second DC auxiliary terminal (224) and a second DC main terminal (223) are disposed on the second housing (221); the second AC main terminal (222) having an input the second rectifier (225) is connected; wherein the second DC main terminal (213) is connected to an output of the second rectifier (225) and to the second DC auxiliary terminal (223) via an internal DC line (226); wherein the charging module (125) includes means for supplying each of the first and second rectifiers (215, 225) with a portion of an AC charging current; and wherein the first DC main terminal (213) is connected to the second DC auxiliary terminal (223) via an external DC line (204) to provide a DC at the second DC main terminal (223) based on the first and second sub-charging currents Charge to provide. Vehicle (120) comprising - An electrical energy store (122); - A charging socket (121) which is adapted to be connected via a charging cable (112) to a charging station (110); and - A charging module (125) according to any one of the preceding claims, wherein the charging module (125) is adapted to provide based on a charging socket (121) provided AC charging current, a DC charging current for charging the energy storage device (122).

Images