DE102018109614A1 - System integration of electrical components in electric or hybrid vehicles - Google Patents

Abstract

Disclosed is an arrangement of at least two fluid and current-carrying components for an electric or hybrid vehicle, wherein the components are integrated in a common housing. Preferably, the at least two components are also controlled by common electronics. Furthermore, an electric or hybrid vehicle is disclosed with an arrangement in whose housing at least two fluid and current-carrying components are integrated.

Description

The invention relates to fluid and current carrying components in electric or hybrid vehicles according to the preamble of claim 1. Such components are e.g. Voltage transformers, high-voltage fluid heaters, battery heaters or coolant pumps.

For vehicles, the trend toward power by means of electric motors or as a hybrid (combustion engine in combination with electric machine) is unmistakable for reasons of environmental compatibility. Both concepts use high voltages (typically 200V - 1,000V) to store the electrical energy in batteries and operate various components. In addition, these vehicles but always have an electrical system, which operates on low voltage (typically 12VDC, 24VDC or 48VDC). This feeds consumers such as lighting, air conditioning compressor or consumer electronics components. For charging the vehicle battery, a third voltage level is then used, namely the 230VAC or 380VAC connection available in the households, which is fed into the vehicle and converted.

In electric and hybrid vehicles, there are various components that are also connected to a fluid circuit that exists in any hybrid or electric vehicle to fulfill your task. In hybrid vehicles, this is the conventional fluid circuit for the internal combustion engine. In both vehicle types, the fluid circuit is then also used for heat dissipation of the various components. The fluid may e.g. a water-glycol mixture or a special heat-transferring liquid.

• - Spannungswandler, z.B.
  • • DC/DC-Wandler: Dieser Spannungswandler setzt die Hochspannung des Fahrzeuges (z.B. Batteriespannung 280VDC) in Niederspannung (z.B. 12VDC) um. Solche Spannungswandler arbeiten bei der Wandlung mit sehr hohen Wirkungsgraden von typischerweise >90%. Daher muss über den Fluidkreislauf nur eine geringe Wärme abgeführt werden.
  • • Ladeeinheit (On Board Charger): Diese Komponente transformiert als AC/DC-Wandler die über das Hausnetz zugeführte Spannung (z.B. 380VAC) auf das Fahrzeug-Spannungs-Batterieniveau (z.B. 280VDC). Auch bei diesem Wandlungsvorgang entsteht Wärme, die vom Fluidkreislauf aufgenommen wird.
  • • DC/AC-Wandler (PIM = Power Inverter Module): Dieser wandelt die in der Fahrzeugbatterie gespeicherte Energie (z.B. 280VDC) wiederum in Wechselspannung zum Betrieb des bzw. der Fahrmotoren um. Auch diese Komponente ist an den Fluidkreislauf angeschlossen.
• - Hochvolt-Fluidheizer (Coolant Heater): Diese Komponente dient der Erwärmung des umlaufenden Fluids zunächst zum Zweck der Erwärmung der Fahrgastzelle. Die im Fluid gespeicherte Wärme wird dann wieder über einen herkömmlichen Wärmetauscher in der HVAC (,Klimakasten‘) an einen Luftstrom abgegeben, der dann in die Fahrgastzelle geleitet wird. Weiterhin dient der Hochvolt-Fluidheizer auch dazu, ein vorgegebenes Temperaturniveau im Fluid zu erreichen. Damit ist dann z.B. auch die Erwärmung anderer Bauteile, wie z.B. der Fahrzeugbatterie möglich. Die EP 2 499 436 B1 offenbart einen derartigen Hochvolt-Fluidheizer.
• - Batterieheizer: Verschiedentlich wird zusätzlich zum Hochvolt-Fluidheizer (zur Erwärmung der Fahrgastzelle) auch ein reiner Batterieheizer eingebaut, der die Akkus auf eine Betriebstemperatur bringt.
• - Kühlmittelpumpe: Sie stellt den Umlauf des Fluids sicher und hängt daher ebenfalls am Fluidkreislauf und an der elektrischen Versorgung (typischerweise im Niederspannungsniveau).

Such components are known per se from the prior art. These components can be in particular:

• - Voltage transformer, eg
  • • DC / DC converter: This voltage converter converts the high voltage of the vehicle (eg battery voltage 280VDC) into low voltage (eg 12VDC). Such voltage transformers work with conversion with very high efficiencies of typically> 90%. Therefore, only a small amount of heat has to be dissipated via the fluid circuit.
  • • Charger unit (On Board Charger): As an AC / DC converter, this component transforms the voltage supplied via the home network (eg 380VAC) to the vehicle voltage battery level (eg 280VDC). Also in this conversion process heat is generated, which is absorbed by the fluid circuit.
  • • DC / AC converter (PIM = Power Inverter Module): This converter converts the energy stored in the vehicle battery (eg 280 VDC) into AC voltage for the operation of the traction motor (s). This component is also connected to the fluid circuit.
• - High-voltage fluid heater (Coolant Heater): This component is used to heat the circulating fluid initially for the purpose of heating the passenger compartment. The heat stored in the fluid is then returned via a conventional heat exchanger in the HVAC ('air box') to an air stream, which is then directed into the passenger compartment. Furthermore, the high-voltage fluid heater also serves to achieve a predetermined temperature level in the fluid. This then, for example, the heating of other components, such as the vehicle battery possible. The EP 2 499 436 B1 discloses such a high-voltage fluid heater.
• - Battery heater: Sometimes, in addition to the high-voltage fluid heater (to heat the passenger compartment), a pure battery heater is installed, which brings the batteries to an operating temperature.
• - Coolant pump: It ensures the circulation of the fluid and therefore also depends on the fluid circuit and the electrical supply (typically in the low voltage level).

• - die Größe und der Bauraumbedarf der Einzelkomponenten,
• - das hohe Gewicht der Einzelkomponenten,
• - der vorrichtungstechnische und montagetechnische Aufwand, und
• - die separat nötige Fluidversorgung und die separaten Fluidanschlüsse.

In arrangements of such separate components of the prior art, the following aspects are disadvantageous:

• - the size and the space requirement of the individual components,
• - the high weight of the individual components,
• - The technical equipment and assembly technical effort, and
• - The separately required fluid supply and the separate fluid connections.

In general, the disadvantage of arrangements of such separate components of the prior art is the lack of system integration in electric or hybrid vehicle.

The object is thus to realize above-mentioned fluid and current-carrying components with system integration, and thus to avoid at least the disadvantages mentioned above.

This object is achieved by an arrangement of fluid and current-carrying components for an electric or hybrid vehicle with the features of claim 1.

The idea according to the invention is to provide an integrated arrangement for an electric or hybrid vehicle, which comprises at least two components carrying fluid and current. In this case, the arrangement has a common housing for the at least two components, which has at least one common fluid inlet and at least one common fluid outlet.

Due to the reduced number of housings, a smaller space requirement and a lower weight are achieved. When merging also the at least two fluid inlets and the at least two fluid outlets (of the at least two individual components of the prior art), the device complexity for the piping or tubing is reduced. Finally, the required amount of fluid and thus again the weight are reduced.

Preferably, the components are a voltage converter (e.g., DC / DC converter, AC / DC converter or DC / AC converter) or a high-voltage fluid heater or a battery heater or a coolant pump.

According to the invention, the number of required attachment points in the affected vehicle is reduced. If e.g. the various components were fastened according to the prior art with three attachment points on the vehicle, then advantageously the common housing is also fixed with three attachment points in the vehicle. In a preferred embodiment, the housing of the arrangement according to the invention has two to four, preferably three attachment points.

In a preferred embodiment, the housing of the arrangement according to the invention has a pressure compensation element. If respective pressure compensation elements are provided on the housings of the components according to the prior art, the number of required pressure compensation elements of the arrangement according to the invention is also reduced.

Further advantageous embodiments of the invention are described in the dependent claims.

• - nur (noch) ein Hochvolt-Anschluss und/oder
• - nur (noch) ein Niedervolt-Anschluss und/oder
• - nur (noch) ein Kommunikationsbus (CAN bzw. LIN) und/oder
• - nur (noch) ein Potenzialausgleichsbolzen

vorgesehen sein. Dadurch ergibt sich eine Reduktion des Verkabelungsaufwandes d.h. deutlich einfacherer und günstigerer Kabelbaum im betroffenen Fahrzeug.Preferably, the electrical connections are collapsed on the housing and thus reduced. In particular, you can

• - Only (still) a high-voltage connection and / or
• - Only (still) a low-voltage connection and / or
• - Only (still) a communication bus (CAN or LIN) and / or
• - only (still) an equipotential bonding bolt

be provided. This results in a reduction of the cabling effort ie significantly simpler and cheaper wiring harness in the affected vehicle.

• - nur noch ein Niedervolt-Teil.
• - nur noch ein Micro-Controller (µC), welcher effektiver ausgelastet wird.
• - ein gemeinsamer Zwischenkreis, d.h. EMV bzw. Stromrippel müssen nur noch einmal gefiltert werden. Dadurch Reduktion der Zahl von teuren und großen Filterbauteilen, wie z.B. Kondensatoren.
• - gemeinsame Entladungsschaltung: Die Filter müssen für die elektrische Sicherheit (z.B. für Arbeiten am System) entladen werden.
• - Reduktion der Ruhestromaufnahme: In jeder einzelnen Komponente gemäß dem Stand der Technik fließt ein gewisser Ruhestrom. Bei erfindungsgemäßer Zusammenfassung der Komponenten zu einem Gesamtsystem mit integrierter Steuerungselektronik wird die Ruhestromaufnahme deutlich gesenkt, was die Standzeit des Fahrzeugs erhöht bzw. die Belastung der Batterie senkt.
• - Reduktion der Leistung an einzelnen Komponenten der Anordnung: durch die Aufnahme der Abwärme einer Komponente, z.B. eines Spannungswandlers, kann die Heizleistung einer anderen Komponente, z.B. eines Fluidheizers, entsprechend reduziert werden. Dies erhöht die Reichweite und somit die Effizienz des betroffenen Fahrzeugs.

A particularly preferred development of the arrangement according to the invention has common control electronics for controlling the at least two components with at least one of the following synergetic effects:

• - only one low-voltage part.
• - Only one micro-controller (μC), which is utilized more effectively.
• - A common intermediate circuit, ie EMC or current ripple need only be filtered again. This reduces the number of expensive and large filter components, such as capacitors.
• - common discharge circuit: The filters must be discharged for electrical safety (eg for work on the system).
• - Reduction of the quiescent current consumption: In each individual component according to the prior art flows a certain quiescent current. When inventively summarizing the components to form a complete system with integrated control electronics, the quiescent current consumption is significantly reduced, which increases the service life of the vehicle or reduces the load on the battery.
• - Reduction of power to individual components of the arrangement: by absorbing the waste heat of a component, such as a voltage converter, the heat output of another component, such as a fluid heater, can be reduced accordingly. This increases the range and thus the efficiency of the affected vehicle.

According to a first variant, a common fluid channel is arranged in the interior of the housing, which extends from the fluid inlet to the fluid outlet. Adjacent to the fluid channel to be cooled areas and / or heat-emitting areas of the components. The regions are arranged one behind the other in the flow direction of the fluid. This is virtually a flow-technical series connection of the components realized.

According to a second variant, a common fluid space is arranged in the interior of the housing, adjacent to the areas to be cooled and / or the heat-emitting areas of the components. This is virtually a fluidic parallel connection of the components realized.

The fluid channel or the fluid chamber is preferably associated with exactly one temperature sensor. If respective temperature sensors are provided on the various components according to the prior art, then the number of required temperature sensors of the arrangement according to the invention is also reduced compared to this.

Preferably, a common electronics space is disposed inside the housing at a particular location (e.g., at the top of the fluid space).

Preferably, common circuit boards are arranged in the electronics compartment, preferably exactly one common circuit board. Thus, the device-technical and assembly technical effort is reduced.

Preferably, the board extends along the side (e.g., top) of the fluid space. Preferably, the board covers the entire page.

Preferably, the board extends parallel to the side of the fluid space and / or parallel to a system boundary between fluid space and electronics space.

In a preferred embodiment, the electronics compartment is substantially disposed in a first housing part (e.g., upper housing part) while the fluid space is substantially disposed in a second housing part (e.g., lower housing part). In this case, the two housing parts via a respective peripheral edge to each other in Appendix.

Furthermore, a connector housing is preferably attached to an outer side (e.g., upper outer side) of the first housing part. The electrical connection and the electrical connection and the communication bus and the equipotential bonding connection are arranged on the connector housing.

In a preferred embodiment, the pressure compensation element is arranged on the first housing part.

In a preferred embodiment, the fluid inlet and the fluid outlet are arranged on a common side (front side) of the fluid space.

Fluid inlet and fluid outlet may also be disposed on different sides of the fluid space.

Thus, according to a particularly preferred embodiment, a DC / DC converter can be combined with a high-voltage fluid heater. This results in a reduction of the overall performance, since by absorbing the waste heat from the DC / DC converter, the heating power of the high-voltage fluid heater can be reduced accordingly. This increases the range of the affected vehicle.

In this case, it is preferred if the high-voltage fluid heater is arranged adjacent to the side on which the fluid inlet and the fluid outlet are arranged, while the DC / DC converter is spaced from this side.

For example, For example, the DC / DC converter and the charging unit are also a particularly advantageous combination of two components according to the invention.

Also, an AC / DC converter and the charging unit or a DC / AC converter and the charging unit can be advantageously combined.

Two embodiments of an arrangement with inventively integrated fluid-carrying components are shown in the figures.

• 1 das erste Ausführungsbeispiel der Anordnung in einer schematischen Darstellung,
• 2 das zweite Ausführungsbeispiel der Anordnung in einer perspektivischen Ansicht, und
• 3 das zweite Ausführungsbeispiel aus 1 in einer perspektivischen Ansicht.

Show it

• 1 the first embodiment of the arrangement in a schematic representation,
• 2 the second embodiment of the arrangement in a perspective view, and
• 3 the second embodiment 1 in a perspective view.

• - DC/DC-Wandler 2: Dieser Spannungswandler setzt die Hochspannung des Fahrzeuges (z.B. Batteriespannung 280VDC) in Niederspannung um (z.B. 12VDC). Der Spannungswandler arbeitet mit sehr hohen Wirkungsgraden von typischerweise >90%. Bei dieser Komponente muss also nur eine geringe Verlustwärme abgeführt werden, was eben an den Fluidkreislauf erfolgt.
• - Hochvolt-Fluidheizer (Coolant Heater) 4: Dieses Komponente dient der Erwärmung desselben umlaufenden Fluids zunächst zum Zweck der Erwärmung der Fahrgastzelle. Die im Fluid gespeicherte Wärme wird dann wieder über einen herkömmlichen Wärmetauscher in der HVAC (,Klimakasten‘) an den Luftstrom abgegeben, der in die Fahrgastzelle geleitet wird. Weiterhin dient diese Komponente auch dazu, ein vorgegebenes Temperaturniveau im Fluid zu erreichen. Damit ist dann z.B. auch die Erwärmung anderer Komponenten, wie z.B. einer Fahrzeugbatterie möglich.

The first embodiment of the arrangement according to the schematic 1 is installed in an electric or hybrid vehicle. The arrangement has in a common housing 1 following two fluid and current carrying components:

• - DC / DC converter 2 : This voltage converter converts the high voltage of the vehicle (eg battery voltage 280VDC) into low voltage (eg 12VDC). The voltage converter works with very high efficiencies of typically> 90%. In this component, so only a small heat loss must be dissipated, which is just done to the fluid circuit.
• - High-voltage fluid heater (Coolant Heater) 4: This component is used to heat the same circulating fluid initially for the purpose of heating the passenger compartment. The stored heat in the fluid is then returned via a conventional heat exchanger in the HVAC ("air box") delivered to the air flow, which is passed into the passenger compartment. Furthermore, this component also serves to achieve a predetermined temperature level in the fluid. This then, for example, the heating of other components, such as a vehicle battery is possible.

In the common housing 1 are an electronics room 6 and a fluid space 8th arranged. In the fluid space 8th open a fluid inlet 10 and a fluid outlet 12 , so that the fluid space can be traversed by the fluid. The fluid is a water-glycol mixture or a special heat-carrying liquid. Furthermore, near the fluid outlet 12 a temperature sensor 14 arranged for the fluid whose signal is a common control electronics of the two components 2 . 4 processed.

Furthermore, on the outside of the housing 1 schematically a potential equalization connection 20 to see, which is connected to the vehicle mass. Outside on the housing 1 are arranged electrical connections. This is a low-voltage connection NV and a high-voltage connection HV ,

Inside the case 1 is in the electronics room 6 arranged the common control electronics, which on the one hand the function of voltage conversion by means of the DC / DC converter 2 and the control of the high-voltage fluid heater 4 takes over. All controls and electronic components are on a common circuit board or board 22 arranged.

In the middle of the case 1 is a system limit 5 as a region of heat transfer from the components 2 . 4 to see the fluid. On the left, the actual high-voltage fluid heater 4 that by means of electrical heating elements 15 , For example, tubular heater, a PTC heater or a thick film heater gives off heat to the fluid. Right is the area of cooling of the DC / DC converter 2 whose loss heat is transferred to the fluid.

The heat transfer from the electronics room 6 to the fluid space 8th takes place over the two rooms 6 . 8th separating system boundary 5 , in which the common power electronics of the high-voltage fluid heater 4 and the DC / DC converter 2 in the electronics room 6 is arranged and at the system boundary 5 is applied. Heat-dissipating elements on the common power electronics are, for example, circuit breakers, transformers and coils. In addition, the electrical heating elements protrude 15 for proper heat transfer to the fluid in the fluid space 8th into it.

The arrangement of the heat transfer areas is in this illustration according to 1 only schematically. If a flow direction in the fluid space 8th can be determined, it may be useful, first with the incoming cold fluid, the cooling of the DC / DC converter 2 then ensure fluid heating via the high-voltage fluid heater 4 perform.

In 2 is an overall view of a second concrete embodiment of the arrangement according to the invention to see. In this case, the second embodiment is similar in principle to the first embodiment. In the second embodiment, in turn, a DC / DC converter 2 with a high-voltage fluid heater 4 combined. The basic design corresponds to a known from the prior art high-voltage fluid heater 4 whose case 1 the invention common housing 1 forms, which is suitable by adapting the installation space to the DC / DC converter 2 to integrate.

The housing 1 has a first housing part 16 , which is designed as a trough-shaped upper part, and in which the electronics compartment 6 is arranged. Furthermore, the housing has 1 a second housing part 18 , which is formed as a trough-shaped lower part, and in which the fluid space 18 is arranged. The two housing parts 16 . 18 lie over respective circumferential edges 24 sealingly against each other.

At a smaller end face of the second lower housing part 18 are one above the other the fluid inlet 10 and the fluid outlet 12 arranged and both formed as a nozzle.

On one long side of the second housing part 18 is an attachment point 25 formed, and on an adjacent long side of the first housing part 16 are two attachment points 25 educated. This has the common housing 1 three attachment points on one side 25 via which the arrangement is fastened to the affected electric or hybrid vehicle.

At an end face of the first housing part 16 is a pressure compensation element 26 intended.

On one side of the first housing part 16 , which is the top in the embodiment shown, is a plug housing 27 attached. In it or on it are the high-voltage connection HV and the low-voltage connection NV with communication bus (CAN or LIN) and the equipotential bonding connection formed as equipotential bonding stud 20 arranged.

In 3 is the second concrete embodiment 2 with removed first housing part 16 to see. In the area of a plane extending from the two edges 24 the two housing parts 16 . 18 is spanned, the system boundary extends 5 , which are fluid-tight in the housing 1 is used.

The common board 22 extends parallel to this plane, from the two edges 24 the two housing parts 16 . 18 is spanned. Here is the board 22 from this plane in the parallel distance (in the embodiment shown above) in the electronics compartment 6 moved into it. The board 22 is about as big as the system limit 5 ,

in view of 3 The advantages of combining all the controls and electrical components of both components 2 . 4 on the common board 22 clear. On the board 22 together are the controls and electrical components of the high-voltage fluid heater 4 and the DC / DC converter 2 arranged.

The high-voltage fluid heater 4 In the embodiment shown has three heating circuits with a total of six electrical connections 28 , The DC / DC converter 2 has eg coils 32 and capacitors 30 ,

In an area adjacent to the fluid inlet 10 and fluid outlet 12 is arranged, is also the common temperature sensor 14 arranged. This senses the temperature of the fluid through the outlet 12 from the fluid space 8th the arrangement of outflowing fluid.

Disclosed is an arrangement of at least two fluid and current-carrying components for an electric or hybrid vehicle, wherein the components are integrated in a common housing. Preferably, the at least two components are also controlled by common electronics. Furthermore, an electric or hybrid vehicle is disclosed with an arrangement in whose housing at least two fluid and current-carrying components are integrated.

LIST OF REFERENCE NUMBERS

1

casing

2

DC / DC converter

4

High-voltage fluid heater

5

system boundary

6

electronics compartment

8th

fluid space

10

fluid inlet

12

fluid outlet

14

temperature sensor

15

electric heating element

16

first housing part

18

second housing part

20

Potential equalization connection

22

circuit board

24

edge

25

attachment point

26

Pressure compensation element

27

plug housing

28

electrical connection

30

capacitor

32

Kitchen sink

HV

connection

NV

connection

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 patent literature

• EP 2499436 B1 [0004]

Claims (15)

Arrangement with at least two fluid-carrying and current-carrying components for an electric or hybrid vehicle, wherein the components are at least one voltage converter (2) and / or a high-voltage fluid heater (4) and / or a battery heater and / or a coolant pump, characterized in that the components are arranged in a common housing (1) which has at least one common fluid inlet (10) and at least one common fluid outlet (12). Arrangement according to Claim 1 wherein the housing (1) has at least one common electrical connection (HV) and / or at least one common electrical connection (NV) and / or at least one common equipotential bonding connection (20) and / or a common pressure compensation element (26). Arrangement according to one of the preceding claims, wherein in the housing (1) a common electronics is provided, via which the at least two components are controllable. Arrangement according to one of the preceding claims, wherein in the interior of the housing, a fluid chamber (8) is arranged adjacent to the areas to be cooled and / or areas of the components to be heated or projecting into these. Arrangement according to Claim 4 , wherein the fluid space (8) is associated with at least one temperature sensor (14). Arrangement according to Claim 4 or 5 , wherein in the interior of the housing (1) adjacent to the fluid space (8) an electronics compartment (6) is arranged. Arrangement according to Claim 6 , wherein in the electronics space (6) a common board (22) of the at least two components is arranged. Arrangement according to Claim 7 , wherein the circuit board (22) extends parallel to the side of the fluid space (8), and / or wherein the circuit board (22) extends parallel to a system boundary (5). Arrangement according to one of Claims 6 to 8th wherein the electronics space (6) is arranged substantially in a first housing part (16), while the fluid space (8) is arranged substantially in a second housing part (18). Arrangement according to the Claims 2 and 9 , wherein on an outer side of the first housing part (16) a plug housing (27) is fixed, on which the electrical connection (HV) and the electrical connection (NV) and the communication bus and the potential equalization terminal (20) are arranged. Arrangement according to one of Claims 4 to 10 wherein the fluid inlet (10) and the fluid outlet (12) are disposed on a common side of the fluid space (8). Arrangement according to one of Claims 4 to 10 wherein the fluid inlet (10) and the fluid outlet (12) are disposed on different sides of the fluid space (8). Arrangement according to one of the preceding claims with two components, which are formed by a DC / DC converter (2) and a high-voltage fluid heater (4). Arrangement according to one of Claims 1 to 12 with two components, which are formed by an AC / DC converter and a high-voltage fluid heater (4). Arrangement according to one of Claims 1 to 12 with two components, which are formed by a DC / AC converter and a high-voltage fluid heater (4).

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