DE202014000328U1 - Charging system for charging an energy storage of an electric vehicle and charging cable therefor - Google Patents

Abstract

Charging system (2) for charging an energy store (18) of an electric vehicle (16), comprising a charging cable (4) with at least one line (12) for transmitting electrical energy between a charging station (14) and the electric vehicle (19), characterized in that the line (12) has a first coupling element (10a) for producing a galvanically isolated coupling arrangement (6) for transmitting the electrical energy to a second coupling element (10b).

Description

The invention relates to a charging system for charging an energy storage device of an electric vehicle, comprising a charging cable with at least one line for the transmission of electrical energy between a charging station and the electric vehicle. Furthermore, the invention relates to a charging cable of such a charging system.

The charging system is used to charge an energy storage, typically a battery, an electric vehicle, for example for passenger transport. Under electric vehicle is understood here any kind of at least one electric motor driven vehicle, in particular also so-called hybrid motor vehicles, in which in addition to the electric motor, an internal combustion engine is still arranged. The electric vehicle typically includes a connector terminal that can be charged by means of a suitable charging cable with a power source, such as a specially designated charging station or a household socket.

From the WO 2011 084736 A2 It is known to provide for charging on demand of an electric vehicle to a charging station, by means of which an electrical plug connection between the charging station and the electric vehicle can be produced. Under charging station is in the following also generally understood an electrical supply network, in particular a household supply network. The charging cable is typically a suitable in terms of the current to be carried and the voltage to be carried line, which connects the electric vehicle with the charging station by means of standardized connectors.

In order to ensure optimum charge of the energy storage and security reasons usually also control electronics is provided, which is either installed in the charging station or integrated directly into the charging cable. In addition, this can communicate with a charging electronics present in the electric vehicle via a data connection and control the charging process in a suitable manner. Furthermore, typically by the charging electronics of the electric vehicle, a corresponding adaptation of a charge provided by the charging station charging size, that is, for example, voltage or current, made to the charge required by the electric vehicle charging size. The adaptation also takes place alternatively for several charging sizes.

Due to the electrical connection of the charging station with the electric vehicle, standards for the charging cable must be met both in the field of household installation and in the field of vehicle components. The disadvantage here is that the merging of these standards has progressed little and therefore complicate ambiguity and conflicting requirements of the standards involved the production of a standard charging cable for a corresponding charging system.

The invention has for its object to provide an improved, standard-compliant charging system and a charging cable for this purpose.

The object is achieved by a charging system with the features of claim 1 and a charging cable with the features of claim 12. Advantageous embodiments, developments and variants are the subject of the dependent claims. The advantages listed below in connection with the charging system, preferred refinements, developments and variants are to be transferred analogously to the charging cable.

For this purpose, it is provided that the charging system for charging an energy store of an electric vehicle comprises a charging cable with at least one line. Charging cable is generally understood to mean a flexurally flexible cable with typically several lines, which are surrounded by an extruded cable sheath, for example. A line here is a single, typically electrical conductor with an insulating sheath. Usually several lines are combined by an additional jacket to the charging cable. For example, a plurality of lines for transmitting a charging current is provided. In addition, the charging cable preferably has functional lines, for example for data transmission. At least one cable is used to transfer electrical energy between a charging station and the electric vehicle. Under charging station here is understood both a direct connection to a household network as well as a specially manufactured and connected to a supply network, such as a high voltage or direct voltage network, connected charging unit. Furthermore, the line has a first coupling element for producing a galvanically separated coupling arrangement for the purpose of transmitting the electrical energy, in particular a charging current, to a second coupling element. The two coupling elements are parts of the coupling arrangement. In addition, this includes, for example, a housing in which the coupling elements are located. During the charging process, the electrical energy is transmitted via the coupling arrangement, without the electric vehicle and the charging station being galvanically connected, in the sense of contacted conductors. The galvanic separation of charging station and electric vehicle eliminates the problem of associated standards by the fact that the charging system is divided into two separate systems that are non-conductive interconnected. The one system is the charging station side subject to the corresponding requirements for a household installation. The second system is subject on the vehicle side to the requirements for charging electric vehicles. Due to the galvanic isolation, therefore, despite the use of a charging cable, the sometimes contradictory standards can be met.

Suitably, the first coupling element and additionally a mechanical coupling element is formed on at least one end of the charging cable for producing a mechanical coupling either with the electric vehicle or the charging station. The mechanical coupling is designed in particular as a plug-in coupling and comprises, for example, a plug and a socket complementary to this. In particular, a clamping or locking device is additionally provided by the falling out or unintentional disconnection of the mechanical coupling and advantageously also the coupling arrangement is prevented. The locking device is designed, for example, as a bayonet lock, as a screw connection or as a snap connection. Furthermore, a positioning device is preferably provided such that the coupling elements of the coupling arrangement are arranged in a defined and suitable position relative to each other. This advantageously ensures an optimal and reproducible connection for transmitting the electrical energy.

In an advantageous embodiment, the second coupling element of the charging system is attached to the charging station and / or the electric vehicle. This eliminates the previously required electrical contact connector. Wear and / or contamination of the electrical contact plug connector associated electrical contact connector, so for example socket and plug, do not occur. Preferably, both ends of the charging cable are each connected via a galvanically isolated coupling arrangement to the charging station or the electric vehicle. In this embodiment, electrical contact plug connections are advantageously completely dispensed with. Alternatively, it is also provided that the charging cable is firmly connected to either the charging station or the electric vehicle. This advantageously reduces the number of separable connections and simplifies handling of the charging system.

In a further advantageous embodiment, the line of the charging cable comprises a first and a second line section, wherein the first coupling element is attached to the first line section and the second coupling element to the second line section. This is understood to mean that the line itself has a galvanic interruption for transmitting the electrical energy. The line is provided with a coupling arrangement such that electrical energy is transmitted, but the two line sections defined by the interruption are galvanically separated from one another. As a result, in particular charging cable for existing electric vehicles and charging stations with corresponding connectors can be produced. An exchange of hitherto built charging station and vehicle-side electrical contact connector is omitted in this case.

Suitably, the first and second coupling elements are each a coil. In particular, in this case the coupling arrangement advantageously produces an inductive coupling. Through this, an energy transfer is realized with simultaneous electrical isolation of the charging station and the electric vehicle. Equally suitable is a capacitive coupling, that is, the coupling elements are designed as capacitors. Here, too, an energy transfer with simultaneous galvanic separation of the charging station and the electric vehicle is made possible. In the case of coils, preferably at least one spool core is provided. In particular, this sits in one or both coils. As a result, the number of windings necessary for achieving a specific inductance is expediently reduced, as a result of which in particular the cost of materials and thus the costs are reduced. Furthermore, a compact design is possible by a reduced number of windings, whereby handling of the charging system is improved.

In a suitable development, the two coils have a different number of windings. In this way, in particular, a transformation of the voltage is made. In particular, the voltage applied to the coupling arrangement on the charging station side is transformed to a value suitable for the electric vehicle. In the case of a conventional conductive connection, on the other hand, the voltage applied to the electric vehicle is limited to the voltage provided by the charging station. The transformation by means of the two coils, a voltage limitation is bypassed. Furthermore, in this case it is preferable to dispense with a transformation of the voltage in the electric vehicle; a corresponding transformer is eliminated, whereby the weight of the electric vehicle and finally its energy consumption is reduced.

In a further suitable development, the first coil is arranged within the second coil. This is in particular a Plug-type mechanical coupling realized. For this purpose, for example, the electric vehicle on a coverable or closable recess in the body, around which a coil is mounted. In addition, the vehicle-side end of the charging cable has a correspondingly smaller-sized coil, which is seated in such a surrounding housing in such a way that the smaller coil is inserted into the larger coil. That is, the housing containing the smaller coil is positively inserted or inserted into the recess surrounded by the larger coil. In particular, at least one coil core is provided which is seated, for example, in the smaller coil. In particular, the coil core is further designed as a plug pin and / or has an extension and is advantageously used for positioning the two coils relative to each other. For this purpose, the plug pin can be suitably inserted into a recess provided for this purpose in the housing comprising the larger coil. The coil core and the coil suitably have an electrically insulating sheath.

In a preferred embodiment, the coupling elements are arranged in the coupled state at a distance from each other, which is smaller than 10 mm and preferably smaller than 3 mm and larger than 0.2 mm. At a distance, this is understood in particular in the case of opposing coils whose axial distance; in the case of nested coils in particular their radial distance. Depending on the distance and a possibly additionally arranged between the coil material, the coupling arrangement has a dielectric strength. This can be interpreted by a suitable choice of the distance such that a voltage breakdown between the coils in the coupling arrangement is avoided during the charging process. The coupling arrangement further has a coupling efficiency, which is adjustable by means of a suitable choice of the distance. The intermediate space can be filled either with air or with another suitable material. In particular, the distance allows complete Einhausen the coupling elements, in particular with a robust and mechanically stable material. As a result, the stability of the coupling arrangement is improved. Furthermore, the susceptibility to interference is reduced by contamination or oxidation. By choosing an electrically insulating material, the safety in handling is further increased.

In a suitable embodiment, the charging cable has an electronic control system. This is understood to mean that the control electronics are integrated in the charging cable, that is, inserted between a connection of the charging station and a connection of the electric vehicle in the charging cable. As a result, for example, the charging process can be monitored and / or controlled; especially if a corresponding control in the charging station is not present, such as in the case of charging via a household socket. Suitably, the electric vehicle additionally has charging electronics which communicate with the control electronics via a data connection. The data connection is in this case designed, for example, as a wired or wireless connection. By way of example, data relating to the requirements of the energy store, such as required voltage and permissible charging current, are communicated via the data connection.

In a preferred embodiment, the control electronics of the charging cable is adjustable depending on a value of at least one charging size, which is provided by the charging station. An adjustment is made here in particular during the manufacture of the charging system by the cable manufacturer. An adjustment for the end customer is preferably not given. Alternatively, such is provided, for example by means of a switch provided for this purpose. Finally, an automatic adjustment by the control electronics itself is provided. Charge size is understood to mean, for example, current, voltage or frequency. The charging size is expediently detected by the control electronics and used as a control variable for a control or regulation of the charging process. In particular, in combination with a data connection, the control electronics makes suitable settings in order to adapt the charging size provided by the charging station to the requirements of the energy store. Alternatively, it is provided that the control electronics of the charging cable is adjustable depending on respective values of a plurality, in particular two charging sizes, which are provided by the charging station. Due to the adjustable control electronics is advantageously also an adaptation of the charging cable to different power grids, for example, in the US and the EU different household electricity networks possible. A single charging cable type can thereby be used in regions with different standards and can be distributed accordingly in different markets. Furthermore, the use of the electric vehicle in combination with the charging cable in such different regions is made possible.

Advantageously, the control electronics of the charging cable is designed such that the charging size provided by the charging station is selected from at least one of the variables voltage and frequency and that a value of the charging quantity is converted into a required value of the charging size by the electric vehicle. For example, from the charging station a voltage of 230 V to Provided and converted by the control electronics in a voltage of 1 kV.

The advantages achieved with the charging system and the charging cable are in particular that an energy storage device of an electric vehicle is charged by means of a charging station via a particularly bendable charging cable such that the electric vehicle and the charging station are galvanically isolated from each other. In this way, in particular the problem of overlapping standards is avoided. Furthermore, in particular an inductive coupling allows an additional transformation of the voltage provided by the charging station such that a corresponding functionality is not necessary on the vehicle side. Also, the galvanically isolated coupling allows complete and thus safe and wear-resistant housing of the coupling elements. In the case of a charging cable end-side coupling arrangement, in particular the wear of the contact plug connector common for electrical contact plug connections is avoided.

Further advantages achieved by the invention are, in particular, that control electronics are integrated in the charging cable. This adjusts depending on the charging sizes provided by the charging station, for example in the form of a transformation or current limitation.

Charge quantities include voltage, current and frequency. The control electronics communicates expediently with a charging electronics present in the electric vehicle and determines, for example, the charging status and the specifications of the energy storage. As a result, the charging process is optimally adapted to the requirements of the energy storage and thus in particular increases the service life of the same.

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

1 a schematic representation of a charging system with a charging cable, which has a coupling arrangement with two inductively coupled line sections,

2 a schematic representation of a further embodiment of a charging system for producing an inductive coupling, wherein a first coupling element is attached to an electric vehicle and a second coupling element to a charging cable,

3 in a schematic representation of a cross section of a coupling arrangement with two nested coils, and

4 a cross section of a charging cable.

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

1 shows a schematic representation of a charging system 2 with a charging cable 4 that is a coupling arrangement 6 with two inductively coupled cable sections 8a . 8b having. The coupling arrangement 6 includes two coupling elements 10a . 10b The charging cable 4 has at least one line 12 on, which is a charging station 14 with an electric vehicle 16 connects to the transmission of electrical energy between the charging station 14 and an energy store 18 of the electric vehicle 16 , The charging station 14 has a socket 20a on, with a complementary plug 20b of the charging cable 4 for producing an electrical contact plug connection 20c is plugged together. The plug 20b and the socket 20a For example, a Schuko plug and a complementary socket after the Standard IEC 60083 , The same applies to the electric vehicle 16 one with its energy storage 18 connected socket 22a on that with a complementary plug 22b of the charging cable 4 for producing an electrical contact plug connection 22c is plugged together. The plug 22a and the socket 22b For example, the type 2 plug and socket are after the Standard IEC 62196 under consideration of Standard IEC 60309 , Such type 2 connectors are also referred to as Mennekes connector. The plug 20b is preferably also a type 2 plug. Conveniently, the charging cable points 4 at least one end, preferably at each of the plugs 20b and 22b , A handle, not shown here for manual gripping by a user. This particular handling of the charging cable 4 facilitated by the user.

The coupling arrangement 6 divides the line 12 in the two pipe sections 8a . 8b , In the charging station-side line section 8b is a control electronics 24 integrated. Coupling arrangement side, the line sections 8a . 8b one coil each 28a . 28b for inductive coupling on. Here are the coils 28a . 28b at a distance 30 arranged relative to each other. In the embodiment shown here is the coupling arrangement 6 housed, which in particular the two coils 28a . 28b are positioned slip-proof and the distance 30 is defined.

2 shows a schematic representation of another embodiment of a charging system 2 with a coupling arrangement 6 , Here is the first coupling element 10a at the end of the charging cable 4 and the second coupling element 10b on the electric vehicle 16 appropriate. The through the coupling arrangement 6 realized coupling is in the here embodiment shown inductively and the coupling elements 10a . 10b are coils 28a . 28b , Between the charging cable 4 and the charging station 14 is through a socket 20a and a complementary plug 20b an electrical contact plug connection 20c realized. A connection between electric vehicle 16 and charging cable 4 is through the coupling arrangement 6 realized. This is indicated by the electric vehicle 16 one the coil 28b comprehensive coupling socket 32a on, in which the on the charging cable 4 end-mounted and in a coupling plug 32b housed coil 28a seated. The coupling plug 32b in this case represents a mechanical coupling element 32c for producing a mechanical coupling 36 dar. The energy storage 18 of the electric vehicle 16 is a charging electronics 34 upstream, the preferred here wirelessly with a in the charging cable 4 integrated control electronics 24 communicated.

3 shows a schematic representation of a cross section of a coupling arrangement 6 with a coupling socket 32a and a coupling plug 32b for producing a mechanical coupling 36 as well as with two nested coils 38a . 38b , The spools 38a . 38b are each connected to a line section, not shown here. In the smaller coil 38a is a spool core 40 , For example, made of iron, used. The coil core 40 has an extension 42 up, out of the coil 38a protrudes. The sink 38a and the coil core 40 are in the coupling plug 32b enclosed. The larger coil 38b is in the to the coupling plug 32b complementarily formed coupling socket 32a enclosed. For the production of the mechanical coupling 36 in particular, the extension 42 positive fit in the coupling socket 32a used. Alternatively, the extension 42 with the spool core 40 also in the coupling socket 32a arranged. Advantageously, at least one detent or snap element, not shown here, is additionally provided for producing a slip-proof mechanical connection.

4 shows a cross section of a typical charging cable 4 , for example, according to 1 as used for a Type 2 connector. The charging cable 4 includes three lines 12 for the transmission of a three-phase charging current.

Furthermore, the charging cable includes 4 a neutral conductor 44 and a grounding 46 , For safe guidance of currents on the order of several amps, the lines 12 . 44 . 46 a cross section of several square millimeters. In the case of a charging current of 32 A, the cross-section of the cables is 12 . 44 . 46 for example, each 6 mm ² . In addition to the wires 12 . 44 . 46 has the charging cable 4 a functional line 48 on, for example, a pilot line to control the connection of the charging cable 4 with the charging station 14 and the electric vehicle 16 is. Further function lines 48 may be provided to, for example, a wired communication between the control electronics 24 and the charging electronics 34 of the electric vehicle 16 to enable. A functional line 48 is, for example, an optical waveguide or a trained as a line temperature sensor for monitoring the charging cable and / or the ambient temperature. Furthermore, it is not of the lines 12 . 44 . 46 . 48 claimed space at least partially with Füllsträngen 50 filled.

LIST OF REFERENCE NUMBERS

2

charging system

4

charge cable

6

coupling arrangement

8a

line section

8b

line section

10a

first coupling element

10b

second coupling element

12

management

14

charging station

16

electric vehicle

18

energy storage

20a

Socket (at a charging station)

20b

Plug (at a charging station)

20c

electrical contact plug connection

22a

Socket (on the electric vehicle)

22b

Plug (on the electric vehicle)

22c

electrical contact plug connection

24

control electronics

28a

Kitchen sink

28b

Kitchen sink

30

distance

32a

coupling sleeve

32b

coupling connector

32c

coupling member

34

charging electronics

36

mechanical coupling (the coupling elements)

38a

smaller coil

38b

larger coil

40

Plunger

42

extension

44

neutral

46

grounding

48

function line

50

filling strand

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

• WO 2011084736 A2 [0003]

Cited non-patent literature

• Standard IEC 60083 [0028]
• Standard IEC 62196 [0028]
• Standard IEC 60309 [0028]

Claims (12)

Charging system ( 2 ) for charging an energy store ( 18 ) of an electric vehicle ( 16 ), comprising a charging cable ( 4 ) with at least one line ( 12 ) for the transmission of electrical energy between a charging station ( 14 ) and the electric vehicle ( 19 ), characterized in that the line ( 12 ) a first coupling element ( 10a ) for producing a galvanically isolated coupling arrangement ( 6 ) for transmitting the electrical energy to a second coupling element ( 10b ) having. Charging system ( 2 ) according to claim 1, characterized in that the charging cable ( 4 ) end the first coupling element ( 10a ) and further a mechanical coupling element ( 32c ) for producing a mechanical coupling ( 36 ) either with the electric vehicle ( 16 ) or the charging station ( 14 ). Charging system ( 2 ) according to claim 1 or 2, characterized in that the second coupling element ( 10b ) at the charging station ( 14 ) and / or the electric vehicle ( 16 ) is attached. Charging system ( 2 ) according to one of claims 1 to 3, characterized in that the line ( 12 ) of the charging cable ( 4 ) a first and a second line section ( 8a . 8b ), that the first coupling element ( 10a ) on the first line section ( 8a ) and the second coupling element ( 10b ) on the second line section ( 8b ) is attached. Charging system ( 2 ) according to one of claims 1 to 4, characterized in that the first and the second coupling element ( 10a . 10b ) one coil each ( 28a . 28b . 38a . 38b ) and this by the coupling arrangement ( 6 ) are inductively coupled. Charging system ( 2 ) according to claim 5, characterized in that the two coils ( 28a . 28b . 38a . 38b ) have a different number of windings. Charging system ( 2 ) according to one of claims 5 to 6, characterized in that the first coil ( 38a ) within the second coil ( 38b ) is arranged. Charging system ( 2 ) according to one of claims 1 to 7, characterized in that the coupling elements ( 10a . 10b ) in a coupled state at a distance ( 30 ) are arranged to each other, which is smaller than 10 mm, and preferably smaller than 3 mm and larger than 0.2 mm. Charging system ( 2 ) according to one of claims 1 to 8, characterized in that the charging cable ( 4 ) a control electronics ( 24 ) having. Charging system ( 2 ) according to claim 9, characterized in that the control electronics ( 24 ) of the charging cable ( 4 ) is adjustable depending on at least one charging size, which is from the charging station ( 14 ). Charging system ( 2 ) according to claim 10, characterized in that the control electronics ( 24 ) of the charging cable ( 4 ) is designed such that the of the charging station ( 14 ) is selected from at least one of the variables voltage and frequency and that a value of the charging quantity in one of the electric vehicle ( 16 ) required value of the charging size is converted. Charging cable ( 4 ) for charging an energy store ( 18 ) of an electric vehicle ( 16 ) with at least one line ( 12 ) for the transmission of electrical energy between a charging station ( 14 ) and the electric vehicle ( 16 ), characterized in that the line ( 12 ) a first coupling element ( 10a ) for producing a galvanically isolated coupling arrangement ( 6 ) for transmitting the electrical energy to a second coupling element ( 10b ) having.

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