DE102022201776B3 - Electrical supply and electrical connection system, drive system, vehicle and method for producing a connection system - Google Patents

Abstract

An electrical supply (145) for a drive system (110) on a vehicle comprises a flange (150) for attachment in a predetermined position on a housing (130) for an electrical device (105); an electrical connector (170); and an electrically insulative retaining bush (165). The flange (150) has a first recess (155) for the passage of an electrical line (125) into the housing (130) and a second recess (160) in which the retaining bush (165) is held. An axial section of the electrical plug (170) is received in the retaining socket (165) in such a way that the plug (170) is plugged into an electrical socket (140) attached to the housing (130) when the flange (150) is in the predetermined Position on the housing (130) is attached.

Description

The present invention relates to an electrical feed and an electrical connection system. In particular, the invention relates to an electrical connection on board a motor vehicle.

A vehicle can be powered by an electric machine. For this purpose, the vehicle includes an electrical energy store, usually in the form of an accumulator, and a power converter. The power converter converts a direct current provided by the energy store into one or more alternating currents that are provided to the electrical machine. By suitably controlling the alternating currents, for example by means of a field-oriented control (also: vector control or d/q control), the electrical machine can assume a predetermined speed or provide a predetermined torque.

Electrical lines leading to the converter can carry large currents and high voltages can be present between them. There is therefore a risk of accidents due to electrical current during installation or maintenance work. The power converter can therefore be accommodated in a housing which has a cutout for electrical lines to pass through. If a line is dismantled, a current flow through the line can be shut off.

In the DE 10 2012 216 451 A1 describes a connector for coupling an electric motor of a vehicle to a power source. The connector includes an electrode and a connector housing houses at least a portion of the electrode. The connector housing is configured to snap into a vehicle powertrain housing via flexible flanges. In this way, the connector can be coupled to the vehicle powertrain housing without additional fasteners.

The DE 10 2019 209 012 A1 relates to a connecting device (1) for electrically coupling an electric machine of an electric drive unit of a motor vehicle to an inverter of the electric drive unit of the motor vehicle. The connection device has a first basic component and a second basic component, the first basic component having an electric machine connector area for establishing a rigid connection of the connection device with the electric machine and the second basic component having an inverter connector area for establishing a rigid connection of the connection device with the inverter.

The WO 2021/197 918 A1 discloses an electrical connection element for fluid-tight electrical contacting, in particular of a vehicle battery, comprising a receptacle made of plastic with a first side and a second side opposite the first side, a contact element which can be electrically contacted from the first side of the receptacle and from the second side of the receptacle, wherein the receptacle is molded onto the contact element and a seal which is arranged between the contact element and the receptacle and is set up to seal a contact area between the contact element and the receptacle.

To determine that a line is being dismantled, a sensor can be used which, for example, detects a removal of a cover on the housing. However, known sensors often have a complex structure, so that the risk of a malfunction is increased. One of the objects on which the present invention is based is to specify an improved electrical feed and an improved electrical connection system for use in an electrical drive system for a vehicle. The invention solves this problem by means of the subject matter of the independent claims. Subclaims reflect preferred embodiments.

According to a first aspect of the present invention, an electric feed for a drive system on a vehicle comprises a flange for attachment to a predetermined position on a housing for an electric device; an electrical plug; and an electrically insulating retainer bushing. In this case, the flange has a first cutout for the passage of an electrical line into the housing and a second cutout in which the retaining bush is held. An axial portion of the electrical plug is received in the retaining socket such that the plug is inserted into an electrical socket mounted on the housing when the flange is mounted in the predetermined position on the housing.

The plug can be used together with the socket as a sensor in order to be able to detect on the part of the housing or the electrical component whether or not the flange is attached to the housing in the predetermined position. The retaining bush can be produced by means of 3D printing, for example from a plastic. The flange can be designed in such a way that it compensates for a predetermined positional tolerance between the plug and the flange. For example, the flange can be elastic.

The holding bush preferably essentially has the shape of a straight hollow cylinder, the base of which corresponds to a circular ring. A longitudinal axis of the cylinder can be an axis of symmetry of the retaining bush with respect to rotation. A rotational symmetry can exist with respect to predetermined angles or any angle. Electrical insulation of the connector relative to the flange can thus be essentially the same in all radial directions. Tracking resistance can be ensured by maintaining predetermined creepage distances in all radial directions.

On its outside, the holding bush can have a holding element which is elastic in the radial direction and is set up to counteract the holding bush being pulled out of the second recess. The holding element is preferably shaped in such a way that it opposes lower forces when it is inserted into the second recess than when it is pulled out. For example, the holding element can be formed in the manner of a barb or a latching element. Furthermore, the retaining element can be fixed in the flange with an undercut.

The flange can have a radial structure for engaging the retaining element, in particular when the retaining element is shaped as a latching element. The structure may include a radial indentation or projection in the second recess, for example a circumferential groove or ring.

The retaining sleeve can have a cavity for receiving adhesive, the cavity being adjacent to a space in the retaining sleeve for receiving the plug. The adhesive can sit between the plug and the retainer socket and thus fix the plug to the retainer socket. In one embodiment, the cavity comprises a radial indentation in the retaining bush, which preferably extends axially. A plurality of indentations can be provided on a circumference around the longitudinal axis.

The plug can preferably be produced in one piece from an electrically conductive material. In this case, contact surfaces of the plug are electrically connected to one another, so that the plug can electrically connect two connections of the socket to one another when it is plugged into the socket.

The connector can be produced as a turned part. For example, the plug can be in the form of a known jack plug which can be plugged into a two-, three- or four-pole electrical jack socket. The plug can be configured to be rotationally symmetrical, particularly in the axial section that protrudes from the retaining bush or that can be inserted into the bush. In the remaining axial section, it can also be rotationally symmetrical. In another embodiment, the plug can be screw-threaded to be screwed into the retaining socket.

According to a further aspect of the present invention, an electrical connection system for a drive system on a vehicle comprises an electrical feed as described herein; and a case for an electric device. The housing has an electrical socket and a third cutout for passage of the electrical wire into the housing so that the wire can pass through the first and third cutouts when the lead is mounted in the predetermined position on the housing. The connection system can be serviceable in an improved manner. The electrical line can be separable from the electrical device.

The flange can be approached or removed substantially perpendicularly to a surface of the housing so that the plug can be securely inserted into or removed from the socket without tilting. For this purpose, a guide pin or a stud bolt can be attached to the housing, which can be inserted into an associated hole in the flange. A nut can secure the flange to the stud. Conversely, a screw can also be screwed through a hole in the flange into a thread in the housing in order to fasten the flange.

One advantage of the invention is tolerance compensation, since with a plug glued firmly into the flange there is a risk that this plug will not fit exactly into the socket on the housing and that contact springs in the socket can be damaged or the plug can be bent/broken off. In the invention, the plug is preferably plugged into the socket first and can then hook into the flange. But the socket and plug are not affected.

The electrical device can be connected to the electrical line and the socket and set up to interrupt a current flow through the electrical line when the plug is not plugged into the socket. Electric current can only flow through the cable when the flange is attached to the housing. The flange can mechanically prevent touching a live part of the line or the electrical device. This can reduce the risk of an electrical accident or a short circuit in the area of the electrical wiring.

The socket may have two contacts which are electrically connected to each other by means of the plug when the flange is fitted in the predetermined position on the housing.

According to yet another aspect of the present invention, a drive system for a vehicle includes an electric machine and a connection system as described herein. The electrical device preferably includes a current transformer for providing currents for the electrical machine. The machine can serve as a prime mover for the vehicle.

According to yet another aspect of the present invention, a vehicle includes a propulsion system as described herein. The vehicle can in particular include a motorcycle or a passenger car. In one embodiment, the vehicle can be used in racing. Advantageously, small dimensions, a small mass, high contact reliability and/or easy assembly of the feed can be particularly relevant.

According to yet another aspect of the present invention, a method of making a connection system as described herein includes the steps of mounting the plug in the receptacle; inserting the plug into the electrical socket on the housing; and sliding the flange onto the retainer bushing and positioning the flange at the predetermined position. Before, during or after the flange is slid on, the electrical line can be routed through the first and second recesses into the housing.

The method can allow for easy and secure assembly of the plug with the retaining bush on the flange. If the flange is removed from the housing again, the retaining socket and the plug can be held on it and also removed.

• 1 ein Fahrzeug mit einem elektrischen Antriebssystem;
• 2 einen Flansch;
• 3 einen Längsschnitt durch eine elektrische Zuführung eines Verbindungssystems;
• 4 bis 6 Ansichten einer beispielhaften Haltebuchse; und
• 7 ein Ablaufdiagramm eines Verfahrens zur Montage einer elektrischen Zuführung

darstellt.The invention will now be described in more detail with reference to the attached figures, in which:

• 1 a vehicle with an electric drive system;
• 2 a flange;
• 3 a longitudinal section through an electrical feed of a connection system;
• 4 until 6 views of an example retaining bushing; and
• 7 a flowchart of a method for assembling an electrical feed

represents.

1 FIG. 1 shows a vehicle 100 with an electric drive system 105. The vehicle 100 preferably comprises a passenger car and can be set up for use in racing. The drive system 105 includes an electric machine 110, a power converter 115 and an electrical connection system 120. The electric machine 110 is set up to drive the vehicle 100. The current converter 115 provides one or more phase-shifted alternating currents to the electric machine 110 in order to control it with regard to a speed and/or a torque provided or consumed. For this purpose, the current converter 115 is connected to the electrical machine 110 or an electrical energy store (not shown) by means of a line 125 .

The electrical connection system 120 includes a housing 130 in which the current transformer 115 is accommodated. On the housing 130 there is a recess 135, which is also referred to herein as the third recess 135, and a socket 140. The connection system 120 also includes an electrical feed 145.

The electrical feed 145 includes a flange 150 with a first recess 155 and a second recess 160, a retaining bushing 165 and a plug 170. The plug 170 includes a first axial portion that is inserted in the retaining bushing 165, and a second axial portion that is set up to be plugged into socket 140 . The retaining bushing 165 is inserted in the second recess 160 and is preferably held on the flange 150 by means of a clamping force.

The flange 150 is configured to be attached to the housing 130 at a predetermined position. In this position, plug 170 is plugged into socket 140. A stud bolt 175 is preferably fitted to the housing 130 and a bore 180 for receiving the stud bolt 175 is fitted to the flange 150 . Several stud bolts 175 and corresponding bores 180 can also be provided. The flange 150 with the retaining socket 165 and the plug 170 can be approached to the housing 130 along a longitudinal axis of the stud 175 until the stud 175 can be guided through the bore 180 and the plug 170 can be inserted into the socket 140 . Once the flange 150 has reached its predetermined position on the housing 130, it can be secured by screwing a nut onto the stud bolt 175. In this position, the first recess 155 in the flange 150 and the third recess 135 in the housing 130 are preferably aligned with one another, so that the line 125 can run through the recesses 135, 155. In the illustrated embodiment, two correspond to each other denden recesses 125, 155 are provided for receiving a line 125 each. Lines 125 can be connected outside of housing 130 to an electrical energy store (not shown) of vehicle 100, for example.

In one embodiment, a lead 125 is connected to different sides of an electrical plug and socket pair (not shown), one of which is attached to the housing 130 and the other of which is attached to the flange 150 . The plug-socket pair can be connected to the housing 130 with the described movement of the flange 150 and separated with an opposite movement.

2 shows a flange 150 for an electrical feed of the type of FIG 1 . One in the viewer 2 facing contact surface of the flange 150 for the housing 130 is preferably flat. The flange 150 can essentially be produced from a flat element and can comprise a metal, in particular a light metal. The flange 150 can preferably be produced by means of machining, in particular drilling, milling and/or turning. In the area of the second recess 160, the flange 150 can be reinforced or lengthened on one side, preferably by a cylindrical extension that 2 on a side of the flange 150 facing away from the viewer. In this case one can also speak of a flange plate 150 .

The retaining sleeve 165 is fully inserted into the second recess 160 and held there. An axial section of plug 170 is accommodated in retaining bush 165, an adjacent axial section perpendicular to the contact surface of flange 150.

3 shows a longitudinal section through an exemplary electrical supply of a connection system 120. The housing 130 with the socket 140 is shown in a left-hand area, and the flange 150 with the plug 170 is shown in a right-hand area. A longitudinal axis of the plug 170 lies in the plane of representation.

The second recess 160 in the flange 150 can be designed as a blind hole or can extend completely through the material of the flange 150 . On a side facing away from the contact surface, the second recess 160 can be closed, for example by means of a closure 305, which can be made of metal or plastic, for example. The closure 305 can, for example, be pressed, glued or screwed into the recess 160 and preferably sealed. In one embodiment, the retaining bushing 165 is threaded or the externally threaded closure 305 cuts the internal threads when screwed in.

The holding bush 165 has elastic holding elements 310 radially on the outside, which are set up to counteract a pulling out of the holding bush 165 in the direction of the contact surface. Insertion of the retaining bushing 165 in the opposite direction is preferably counteracted less strongly. Retaining bushing 165 can thus function in the manner of a dowel to hold plug 170 to flange 150 . A plurality of retaining elements 310 can be offset on a circumference around the longitudinal axis of the retaining bushing 165 . An optional radial structure 315 is provided on a radial inner side of the second recess 160, which presently comprises a circumferential ridge or ring that extends radially inward. In another embodiment, a radial indentation can also be provided, which extends radially outwards with respect to the retaining bush 165 .

In the present case, in the area between the housing 130 and the flange 150 , there is a seal 320 in the form of an O-ring running around the plug 170 . The seal 320 can be held in a corresponding depression on the flange 150 by means of a press fit.

4 until 6 12 shows views of an exemplary retainer bushing 165. The views are referenced but are not necessarily to scale. 4 shows a side view, 5 the same view in longitudinal section and 6 an axial view of the retaining bush 165.

In 5 and 6 An embodiment can be seen in which one or more cavities 505 are provided on the inside of the retaining socket 165, which lie between the retaining socket 165 and the plug 170 when the plug 170 is inserted into the retaining socket 165. A cavity 505 can accommodate an adhesive, a sealant or another compound that preferably has an adhesive effect between the retaining socket 165 and the plug 170 . The mass can be introduced into the cavity 505 in a liquid or pasty state and can harden there after the plug 170 has been inserted. The cavities 505 shown are evenly distributed over a circumference around the longitudinal axis of the retaining bush 165 and extend parallel thereto.

7 shows a flowchart of a method 700 for installing an electrical feed 145. It should be noted that the steps shown do not all have to be carried out and that the order shown is exemplary. A specialist can easily develop other sequences himself.

In a first step 705, the retaining bushing 165 can be provided with an adhesive, which can be applied in particular to a region of a recess in the retaining bushing 165 that delimits a cavity 505, as with reference to FIG 5 and 6 is described.

In a step 710 the plug 170 can be pushed into the holding socket 165 . If adhesive or a similar mass was used in step 705, it can be cured in step 715.

Then in a step 720 the plug 170 can be plugged into the socket 140 attached to the housing 130 . In a step 725 the flange 150 can be slid onto the retaining bush 165 .

In a step 730, the flange 150 on the housing 130 can be brought into the predetermined position, which usually includes abutment against the housing 130. To slide on or to position the flange 150, it may be necessary to thread one or more studs 175 attached to the housing 130 into corresponding bores 180 of the flange 150 at the same time. During positioning, the retaining socket 165 can provide the plug 170 with a predetermined amount of play so that the plug 170 is optimally aligned with the socket 140 . The play can be perpendicular to the contact surface or allow the plug 170 to tilt from a direction perpendicular to the contact surface. In one embodiment, the curing of the adhesive in step 715 is performed only after the flange 150 is positioned in step 730 .

Thereafter, the flange 150 can be removed from the housing 130 again. It should be noted that the electrical lead 125 does not necessarily have to pass through the recesses 135, 155 in order to align and attach the plug 170 to the flange 150 in the method 700. However, in a subsequent use of lead 145, line 125 is typically used at this point.

reference list

100

vehicle

105

electrical facility

110

electric drive system

115

Power converter

120

electrical connection system

125

electrical line

130

Housing

135

third recess

140

Rifle

145

electrical feed

150

flange

155

first recess

160

second recess

165

retaining bush

170

Plug

175

studs

180

drilling

305

closure

310

elastic holding element

315

radial structure

320

poetry

505

cavity

700

Proceedings

705

Glue the retaining bush

710

Push plug into retaining socket

715

cross-link adhesive

720

Plug the connector into the socket on the housing

725

Push the flange onto the retaining bush

730

Position flange on housing

Claims (13)

An electrical lead-in (145) for a drive system (110) on a vehicle, the lead-in (145) comprising: a flange (150) for attachment to a predetermined position on a housing (130) for an electrical device (105); an electrical connector (170); and an electrically insulative retaining bush (165); wherein the flange (150) has a first recess (155) for the passage of an electrical line (125) into the housing (130); the flange (150) having a second recess (160) in which the retaining sleeve (165) is retained; an axial portion of the electrical plug (170) being received in the retaining socket (165); such that the plug (170) is plugged into an electrical jack (140) attached to the housing (130) when the flange (150) is attached to the housing (130) in the predetermined position. feed (145) after claim 1 , wherein the retaining bushing (165) essentially has the shape of a right hollow cylinder. feed (145) after claim 1 or 2 , wherein the holding bushing (165) has a radially elastic holding element (310) on its outside, which is set up to counteract a pulling out of the holding bushing (165) from the second recess (160). feed (145) after claim 3 , wherein the flange (150) has a radial structure (315) for engaging the retaining element (310). Lead (145) according to one of the preceding claims, wherein the retaining sleeve (165) has a cavity (505) for receiving adhesive, the cavity (505) adjoining a space of the retaining sleeve (165) for receiving the plug (170). Lead (145) according to one of the preceding claims, wherein the plug (170) can be produced in one piece from an electrically conductive material. Feeder (145) according to one of the preceding claims, in which the plug (170) can be produced as a turned part. Electrical connection system (120) for a drive system (110) on a vehicle, the connection system (120) comprising the following elements: an electrical feed (145) according to any one of the preceding claims; a housing (130) for an electrical device (105); wherein the housing (130) has an electrical socket (140) and a third recess (135) for the passage of the electrical line (125) into the housing (130); so that the lead (125) can pass through the first and third recesses (135) when the lead (145) is mounted in the predetermined position on the housing (130). Connection system (120) according to claim 8 , wherein the electrical device (105) is connected to the electrical line (125) and the socket (140) and is set up to interrupt a current flow through the electrical line (125) when the plug (170) is not in the socket ( 140) stuck. Connection system (120) according to claim 9 , wherein the socket (140) has two contacts which are electrically connected to one another by means of the plug (170) when the flange (150) is attached to the housing (130) in the predetermined position. Drive system (110) for a vehicle, wherein the drive system (110) has an electric machine and a connection system (120) according to one of Claims 8 until 10 includes; wherein the electrical device (105) comprises a current transformer (115) for providing currents for the electrical machine (105). Vehicle (100) comprising a drive system (110). claim 11 . Method (700) for producing a connection system (120) according to one of Claims 8 until 10 ; the method (700) comprising the steps of: mounting (710) the plug (170) in the retaining socket (165); plugging (720) the plug (170) into the electrical socket (140) on the housing (130); and sliding (725) the flange (150) onto the retaining bush (165) and positioning (730) the flange (150) at the predetermined position.

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