DE202015106844U1 - Plug with a vehicle charging cable of an electric or hybrid vehicle - Google Patents

Abstract

Plug (1), which is connected to a charging cable (2), in particular to a vehicle charging cable of an electric or hybrid vehicle, and a plug housing (3), as well as live electrical contacts (4a, 4b) for a charging current, in particular a battery of the electric or hybrid vehicle, wherein in the plug housing (3) at least one temperature sensor (5a, 5b) is arranged for charge control and / or charge monitoring, characterized in that the temperature sensor (5a, 5b) with a connection element (51) made of thermally conductive material is directly thermally and mechanically connected to one of the live current contacts (4a, 4b), wherein the connection element (51) is a part of the temperature sensor (5a, 5b).

Description

Technical area

The invention relates to a plug according to the preamble of claim 1.

In electric or hybrid vehicles, the battery is charged via a charging cable. The charging cable is equipped with a mains plug. The power plug can be connected to a household socket.

The charging current is often regulated as a function of a temperature of the plug contacts. Here, temperature sensors are used.

Known charging controls by temperature sensors often have the disadvantage that they are relatively sluggish. It may take up to 20 minutes for a temperature actual value to be recorded.

Also, changes must be made to the plug to integrate the temperature sensors in this.

State of the art

From the DE 10 2010 014 024 A1 a plug of the generic type is known in which a temperature sensor or a PTC or NTC sensor is integrated. The sensor is positioned to sense a temperature near a connection between the contact plugs and the jacks. The temperature sensor may be encapsulated in a housing by injection molding.

Object of the invention and solution

The invention has for its object to provide a plug of the generic type, which allows a fast charge control with low production costs.

This object is achieved by a plug with the features specified in the characterizing part of claim 1 in conjunction with its preamble features.

The invention is based on the idea to connect the temperature sensor directly to the plug thermally and mechanically to allow rapid temperature detection. In this case, commercially available sensor elements can be used.

Advantages of the invention

The connector according to the invention has the advantage that on the one hand no changes to the housing of the plug must be made and on the other hand commercially available sensors can be used without additional elements.

In addition, by the invention sufficient electrical insulation is taken into account, without the need for heat shrink tubing and the like. In fact, sensors integrated into the connector must comply with standards that ensure that there is sufficient distance between the power supply and the sensor cables and sufficient electrical insulation. For example, shrink tubing could be used that electrically isolates the sensor control lines and / or other conductive parts. These additional elements are eliminated by the inventive design. For live parts, a distance of 3 mm must be maintained for insulation reasons. By the invention can therefore be dispensed with shrink tubes, the assembly is cumbersome

By plug according to the invention, it is possible to significantly shorten a temperature-actual value acquisition.

The invention is based on the recognition that for charge control or charge monitoring, a temperature of the contacts of a plug is used. The higher the charge current, the higher the temperature of the plug contacts.

At high current loads or high charging currents, the contacts of the connector heat up. The idea is to monitor the temperature in the near region of the connection between cable and plug by means of a sensor according to the invention, which is mounted at a distance.

Due to the fast and efficient temperature transfer, a regulation of the power or the current is many times faster than known solutions.

The connection element is part of the temperature sensor. The commercial connection element already has such a connection element. The connection element is connected as standard to the sensor body.

As a temperature sensor, each component can be used, for example, changes its resistance as a function of temperature.

For example, hot-letters (NTC) can be used. These reduce their resistance to temperature increase. They are based on metal oxides or semiconductors. Such a component is also called a thermistor.

It is also possible to use PTC thermistors. These increase their resistance with temperature increase.

For example, a sensor type NTCALUG01A from Vishay is used.

Also usable are platinum measuring resistors. These have a nearly temperature-linear resistance profile. They can be used for temperatures between -200 ° C and +850 ° C.

Also conceivable is the arrangement of silicon measuring resistors. These can be used in the temperature range from -50 ° C to +150 ° C.

Basically, a ceramic PTC thermistor can be used. This has a strong resistance increase at a material-specific temperature.

As a temperature sensor and other components can be used, which provide an editable electrical signal directly. For example, integrated semiconductor temperature sensors or solid-state circuits can be used, which deliver a current proportional to their temperature.

Alternatively, a heat sensor with quartz crystal can be used as a measuring element. The resonant frequency of the oscillating quartz changes depending on the temperature and can be measured very precisely.

Instead, thermocouples can be installed just as well. These convert a temperature difference by the so-called Seebeck effect into an electrical voltage.

Not to be excluded are pyroelectric materials. These change the charge carrier density at their surface with temperature fluctuations by changing the spontaneous polarization.

Also suitable are so-called Curie effect temperature sensors. These consist of a permanent magnet, which adheres below the Curie temperature to ferromagnetic material and drops above this temperature, thereby actuating a switch.

Basically, the use of fiber optic temperature sensors is possible. They are based on the so-called Raman effect or the temperature-dependent refractive index change in fiber Bragg grating sensors (FBGS).

So it is a variety of temperature sensors or heat sensors, temperature sensors, heat sensors and the like possible.

Advantageous embodiments of the invention and further advantages

Further advantageous embodiments of the invention are characterized in the subclaims.

In an advantageous embodiment of the plug according to the invention it is provided that the connection element consists of metal. The high thermal conductivity of the metal ensures fast heat transfer from the pin to the sensor and fast indirect current measurement.

Shrink tubing or other insulation can be omitted if a commercially available sensor is used, in which the sensor lines are already designed as electrically insulated lines.

In an advantageous embodiment of the invention, the connection element is designed as connections with a flat connection body and a bore present in the connection body. The connection cable of the L-phase or N-phase current conductor can pass through the hole in the connector body of the sensor

In another advantageous development of the connector according to the invention, it is provided that the diameter of the connection bore of the connection element is greater than a diameter of a conductor, in particular a strand, of a connection cable and is smaller than a diameter of the live current contact. During assembly, the connector body is on the connector pin a stop, which simplifies installation.

So that the connection element has a good heat contact on the one hand and a fixed mechanical connection on the other hand, in a further preferred embodiment of the invention it is provided that the connection element is firmly curved with the conductor of the current-carrying connection cable. Subsequently, the connection element can be soldered in with the strand of the conductor and the pin.

In an advantageous embodiment of the plug according to the invention, a temperature sensor is provided for each of the live current contacts, so that a total of two temperature sensors are present. This has the advantage that different contact connections of the N- and L-conductors can be averaged, so that a more accurate indirect current measurement is possible.

Optimally, the sensors can be integrated in the connector housing if the temperature sensor consists of a cylindrical sensor housing and one on one end face of the sensor housing protruding connecting element consists. A sufficient insulation distance of the sensor lines is given if connection lines of the sensor are arranged on the opposite end face of the sensor housing.

Appropriately, the sensor is designed as a thermocouple, in particular as an NTC thermistor. This allows an accurate measurement at low cost.

Commercially available sensors can be used without changes of the connector housing when the connection element is arranged at an angle of approximately 90 ° to the current contact of the plug. The metal connection element of the sensor does not have to be bent or processed in any other way.

For electric cars, a standardized power plug is preferably used for an AC power supply.

embodiments

Embodiments will be explained in more detail with reference to the drawings, wherein further advantageous developments of the invention and advantages thereof are described.

Show it:

1 a first perspective view of an embodiment of the plug according to the invention,

2 a second perspective view of the plug according to the invention,

3 a third perspective view of the plug according to the invention,

4 a fourth perspective view of the plug according to the invention,

5 a perspective view of a sensor for the plug,

6 a view of the sensor seen from above,

7 a side view of the sensor, and

8th a view of the sensor from below.

The figures show a plug 1 for use in a German power grid.

The plug 1 is with a vehicle charging cable 2 connected to an electric or hybrid vehicle. The charging cable 2 is in 2 as a dashed line 2 indicated. The plug 1 has a connector housing 3 as well as live power contacts 4a . 4b for a charging current of a battery of the electric or hybrid vehicle. In the connector housing 3 are two temperature sensors 5a . 5b intended for charge control. Instead of a regulation, an additional current or temperature monitoring is conceivable, wherein the actual charge control could be effected by an external actual detection element. The terms control and monitoring here include other terms, such as control, protective measures and the like and are to be interpreted broadly here.

With the sensors 5a . 5b connected control lines 50 that are shown in the figures are in the charging cable 2 guided.

The plug 1 is designed as a three-pole plug for a conductor L, a neutral conductor N and a protective conductor PE. This can be as a three-pole Schuko plug according to German standards with two lateral or opposite PE contacts 6 , in the 3 are marked, and two front plug contacts 7 . 8th be designed. This can also be used as a three-pin plug 1 be executed for another country standard with three front plug contacts (not shown here).

The figures thus illustrate a plug 1 with a charging cable 2 , in particular connected to a vehicle charging cable of an electric or hybrid vehicle, and a connector housing 3 , as well as live power contacts 4a . 4b for a charging current, in particular a battery of the electric or hybrid vehicle, wherein in the connector housing 3 at least one temperature sensor 5a . 5b is arranged for a charge control and / or a charge monitoring. Every temperature sensor 5a . 5b is thermally conductive and mechanically connected to a connection element made of thermally conductive material directly to one of the live current contacts, wherein the connection element is a part of the temperature sensor.

Every temperature sensor 5a . 5b is with a connection element 51 made of thermally conductive material and that metal or a copper piece with tin coating directly with one of the live current contacts 4a . 4b thermally and mechanically connected. The connection element 51 is a part of the temperature sensor 5a respectively. 5b ,

This sensor 5a . 5b already has isolated sensor cables 50 on. The sensor cables 50 are thus designed in series as electrically insulated cables.

Each connection element 51 is as connections 53 with a flat connection body 54 and one in the connection body 54 ( 3 ) existing hole 58 ( 1 ). The diameter of the connection bore of the connection element should be greater than a diameter of a conductor L, N, in particular a strand of a connection cable 52 ( 3 ) be. The diameter is smaller than a diameter of the live current contact.

The connection element 51 is firmly bent with the conductor of the current-carrying connection cable. For each of the live power contacts 4a . 4b is each a temperature sensor 5a . 5b ( 1 ) is present, so that a total of two temperature sensors are available.

Every temperature sensor 5a . 5b consists of a cylindrical sensor housing 55 ( 3 ) and from the one end 56 of the sensor housing 55 protruding connection element 51 , At the opposite end 57 the sensor housing preferably connecting lines of the sensor are arranged. The sensor is designed as a thermocouple, in particular as an NTC thermistor. The connection element 51 is arranged at an angle of about 90 ° to the power contact of the plug, as the 1 to 4 continue to show.

The housing 55 can be made of metal and integral with the connection element 51 be connected, like the 5 to 7 demonstrate.

Every temperature sensor 5a . 5b is eg of the type NTCALUG01A of VISHAY.

The cable length of the integrated L1 or L1 + L2 is eg 30 mm to 50 mm, (L1 = 38.1 mm, L2 3.81 mm) Sensor cables The sensor length L3 is eg 10 to 20 mm (L3 = 16.26 mm). The diameter D1 of the bore is eg 5 to 5 mm (D1 = 3.68 mm). The width D2 of the connection element 51 is eg 6 to 8 mm (D2 = 7.14 mm). The thickness T of the connection element is, for example, 0.8 to 1.3 mm (T = 1.016 mm).

The sensor includes a thermistor chip with epoxy coating. The metal ring or the sensor housing best of tinned copper. The sensor cables are PTFE insulated. The wire of the sensor cables is tinned.

Although the plug is a standard power plug for an AC power network, but also a different type of plug or another charging voltage can be used, which is suitable to charge the battery of the electric car.

The invention is therefore not on the example of the 1 to 7 limited. For example, other sensors, such as PTC sensors, can be used.

LIST OF REFERENCE NUMBERS

1

plug

2

Vehicle charging cable

3

plug housing

4a

current contact

4b

current contact

5a

temperature sensor

5b

temperature sensor

6

PE contacts

7

plug contact

8th

plug contact

50

control lines

51

connecting element

52

connecting cable

53

connections

54

connection body

55

sensor housing

56

First front page

57

Second front side

58

drilling

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

• DE 102010014024 A1 [0006]

Claims (10)

Plug ( 1 ), with a charging cable ( 2 ), in particular connected to a vehicle charging cable of an electric or hybrid vehicle, and a plug housing ( 3 ), as well as live current contacts ( 4a . 4b ) for a charging current, in particular a battery of the electric or hybrid vehicle, wherein in the connector housing ( 3 ) at least one temperature sensor ( 5a . 5b ) is arranged for a charge control and / or a charge monitoring, characterized in that the temperature sensor ( 5a . 5b ) with a connection element ( 51 ) of thermally conductive material directly with one of the live current contacts ( 4a . 4b ) is thermally and mechanically connected, wherein the connecting element ( 51 ) a part of the temperature sensor ( 5a . 5b ). Plug according to claim 1, characterized in that the connecting element ( 51 ) consists of metal. Plug according to claim 1, characterized in that the sensor lines ( 50 ) are designed as electrically insulated lines. Plug according to claim 1 or 2, characterized in that the connecting element ( 51 ) as connections ( 53 ) with a flat connection body ( 54 ) and one in the connecting body ( 54 ) existing hole ( 58 ) is executed, wherein the diameter (D1) of the connection bore ( 58 ) of the connecting element ( 51 ) is in particular larger than a diameter of a conductor, in particular a strand of a connecting cable and is smaller than a diameter of the live current contact. Plug according to claim 3 or 4, characterized in that the connecting element ( 51 ) with the conductor of the current-carrying connection cable ( 52 ) is firmly gekimmpt. Plug according to one of the preceding claims, characterized in that for each of the live current contacts ( 4a . 4b ) a temperature sensor ( 5a . 5b ), so that a total of two temperature sensors ( 5a . 5b ) available. Plug according to one of the preceding claims, characterized in that the temperature sensor ( 5a . 5b ) from a cylindrical sensor housing ( 55 ) and from the one at the end ( 56 ) of the sensor housing ( 55 ) projecting connection element ( 51 ), wherein at the opposite end ( 57 ) of the sensor housing ( 55 ) preferably connecting lines ( 50 ) of the sensor ( 5a . 5b ) are arranged. Plug according to claim 7, characterized in that the sensor ( 5a . 5b ) is designed as a thermocouple, in particular as an NTC thermistor. Plug according to one of the preceding claims, characterized in that the connecting element ( 51 ) at an angle of about 90 ° to the current contact ( 4a . 4b ) of the plug is ang eordnet.  Plug according to one of the preceding claims, characterized by an embodiment as a standardized power plug for an AC power supply.

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