DE202019100047U1 - High-voltage connector - Google Patents

Abstract

High-voltage connector (100) for a vehicle, in particular an electric vehicle, with
- A base body (103) having a connection geometry (104) which is adapted to be inserted into an opening (106) through an electrically conductive wall (108) of a component (110) of an energy system of the vehicle; and
- An integrated into the base body (103) implementing means (112) which is adapted to at least one electrical conductor (114) of a high-voltage line (116) of the energy system electrically isolated through the opening (106) to lead, wherein the lead-through device (112) a plug contour (120) embodied in the main body (103) and an interlock device (102) for detecting a connection state of the plug contour (120), wherein a fixed part of the interlock device (102) is integrated into the plug contour (120), wherein the interlock device ( 102) is adapted to generate a connection state-dependent electrical signal for an evaluation.

Description

Technical area

The present invention relates to a high-voltage connector for a vehicle, in particular an electric vehicle.

State of the art

The present invention will be described below mainly in connection with transmission elements for vehicle electrical systems. However, the invention can be used in any application in which electrical loads are transmitted.

Electrical energy for driving a vehicle can be transported in the vehicle via cable from a traction battery of the vehicle to a power electronics of the vehicle and further to at least one electric motor driven electric machine of the vehicle. In the opposite direction, the electrical energy can be transported via the cable from the generator-operated electric machine to the power electronics and on to the traction battery. Both on the electric machine and on a housing of the power electronics as well as on a housing of the traction battery cables can be connected via detachable connectors.

Description of the invention

An object of the invention is therefore to provide a means for monitoring a connector using structurally simple means possible.

The object is solved by the subject matter of the independent claim. Advantageous developments of the invention are specified in the dependent claims, the description and the accompanying figures.

The invention relates to a high-voltage connector for a vehicle, in particular an electric vehicle, which has a base body with a connection geometry that is designed to be inserted into an opening through an electrically conductive wall of a component of an energy system of the vehicle. Furthermore, the high-voltage connector has an integrated into the main body bushing, which is adapted to lead at least one electrical conductor of a high-voltage line of the energy system electrically isolated through the opening. The feedthrough device has a plug contour executed in the main body and an interlock device for detecting a connection state of the plug contour. A fixed part of the interlock device is integrated in the plug contour. The interlock device is designed to generate a connection state-dependent electrical signal for evaluation electronics.

An energy system of a vehicle can be understood as a line system designed for providing and transmitting high electrical powers with associated electronic components. In this case, the electrical power can be transmitted using high voltage and high electrical current flows. For example, the energy system can connect a traction battery of the vehicle to at least one electric machine of the vehicle and have at least one switching box for controlling the energy transmission.

A high-voltage connector can be an interface component which leads out at least one electrical conductor for conducting the high-voltage voltage through an opening from a component of the energy system and thereby prevents a direct electrically conductive contact with a housing of the component. A base body may be made of an electrically insulating material, for example a plastic material. At the high-voltage connector, the conductor can be separated by separating the plug contour and the counterpart and re-connected by plugging the counterpart with the plug contour. The high-voltage connector may be a cable-side connector or a device-side connector. A connection geometry may be a counterpart to the breakthrough or may be complementary thereto. The connection geometry may provide abutment surfaces, abutment surfaces, and / or attachment points to the housing. The electrical contact is prevented by an implementation device. The feed-through device provides electrically insulating wall thicknesses and clearance and creepage distances adapted to prevent contact with the high-voltage voltage used, to the connection geometry or the wall of the component.

The term "high voltage" refers to a voltage level greater than 65 V. In the motor vehicle, such connectors are designed for a voltage level (high voltage voltage) of at least 400 V, typically about 480 V or for use above 800 V, typically about 900 V to 980 V. The at least one conductor is arranged to conduct the high voltage and corresponding electrical current flows. The conductor can also be referred to as electrical line.

The at least one conductor may have a jacket, also referred to as a cable jacket, as a cable shield. When a variety of ( At least two) ladders is provided, so they can be enclosed by a total screen or overall coat. the high-voltage connector may have at least one second conductor. The conductors may each have a cable jacket comprising the respective conductor. The conductors may form a cable with a total screen enveloping the conductors. The overall screen can be designed to be connected or connected to the housing of the component in which the high-voltage leadthrough or the high-voltage connector is mounted as a device-side connector via a ground connection.

The connection state-dependent signal can signal whether a counterpart to the plug contour is inserted as intended in the plug contour or not. By plugging in, for example, a circuit can be closed at the interlock device and thus the signal is generated. For this purpose, for example, an interlock bridge can be integrated into the counterpart. When disconnecting the plug contour and the counterpart, the circuit can be interrupted.

An electrical pole of the interlock device can be electrically connected to a ground connection of the base body. An evaluation of the interlock device may also have a ground contact. A part of the circuit for signal transmission can thus take place via the electrically conductive wall of the component. Thus, a wire of a signal line can be saved from the interlock device to the transmitter.

The interlock device can have a piezo element integrated into the main body for generating a connection state-dependent voltage signal. The piezoelectric element may be arranged in the base body such that it is deformed or placed under mechanical tension when the counterpart is inserted. Due to the piezoelectric effect, the piezo element reacts to the deformation or the mechanical stress with an electrical voltage applied to opposite poles. The piezo element is thus a voltage source. The voltage signal can be evaluated.

An electrical pole of the piezoelectric element may be electrically conductively connected to the conductor. The piezoelectric element does not conduct current, but reacts to the high voltage with a deformation. At the other pole of the piezo element, the high-voltage is not applied. The voltage signal generated by the deformation when inserting the counterpart superimposed on the high voltage and can be tapped on the conductor. The other pole may be connected via a single wire of a signal line or via the ground contact.

list of figures

• 1 eine Darstellung eines Hochvoltsteckverbinders mit einer Interlockeinrichtung gemäß einem Ausführungsbeispiel; und
• 2 eine Darstellung eines Hochvoltsteckverbinders mit einem Piezoelement gemäß einem Ausführungsbeispiel.

Hereinafter, an advantageous embodiment of the invention will be explained with reference to the accompanying figures. Show it:

• 1 an illustration of a high-voltage connector with an interlock device according to an embodiment; and
• 2 an illustration of a high-voltage connector with a piezoelectric element according to an embodiment.

The figures are merely schematic representations and serve only to illustrate the invention. Identical or equivalent elements are consistently provided with the same reference numerals.

Detailed description

For ease of understanding, reference numerals will be used in the following description 1-2 retained as a reference.

1 shows a representation of a high-voltage connector 100 with an interlock device 102 according to an embodiment. The high-voltage connector 100 has a basic body 104 made of an electrically insulating material. The main body 103 has a connection geometry 104 on. The connection geometry 104 is trained to be in a breakthrough 106 through an electrically conductive wall 108 a component 110 an energy system of an electric vehicle to be used and at the breakthrough 106 seal.

The main body 103 forms an implementation device 112 for performing at least one electrical conductor 114 a high-voltage line 116 of the energy system through the breakthrough 106 out. The electrical conductor 114 may be, for example, a bus bar or a wire. The implementation facility 112 provides a dielectric strength to the wall 108 by a to the high voltage of the conductor 114 adapted wall thickness of the electrically insulating material between the electrical conductor 114 and the wall 108 for sure. Furthermore, the implementation device 112 Air and creepage distances adapted to the wall by the high-voltage voltage 108 a rollover resistance of the high-voltage connector 100 for sure. The air and creepage distances, for example, by collar or spouts on the head 114 to be provided.

The high-voltage line 116 is here through a screen 118 shielded executed. The screen 118 is about a ground connection 120 of the basic body 103 electrically conductive with the wall 108 connected. umbrella 118 and ladder 114 are electrically isolated from each other by insulation material. The high-voltage line 116 can be referred to as high-voltage cable.

The implementation facility 112 has a plug contour 120 and a matching counterpart 122 on. The high-voltage line 116 here has two electrical conductors 114 on, isolated from each other by the implementation device 112 are guided. The ladder 114 are in the plug contour 120 divided and are connected when plugged in or when removing the counterpart 122 separated. At the counterpart 122 is the multi-wire high-voltage line 116 attached. Also the screen 118 is at the plug contour 120 divided.

The interlock device 102 has two poles, those with plugged counterpart 122 through one in the counterpart 122 integrated interlock bridge 124 be shorted. Through the interlock bridge 124 Thus, a circuit of a monitoring electronics of the component can be closed, can be detected by the, whether the high-voltage connector 100 connected is.

In one embodiment, one of the poles is a ground connection 126 connected. Thus, the circuit can be closed via the wall of the component and a signal line can be saved.

In other words, an interlock is presented via a case closure. In this case, a simplified interlock detection by use of the housing or mass-leading components.

Power cables are connected to high-voltage batteries (HV batteries) and / or high-voltage switch boxes (HV switch boxes) using HV plug-in systems. These HV plug-in systems are monitored with a high-voltage interlock (HV-Interlock) for open contacts in order to prevent associated dangers. For example, in the event of an unwanted opening of the interlock loop, the battery is disconnected on all poles. For example, two LV lines (low-voltage lines) can be routed to each HV plug-in system and interconnected as a signal loop. With a signal generator, a signal of, for example, 10 mA can be generated and transmitted via the first line. When plugged HV mating connector with matching HV-Interlock bridge can be received with a signal detector, the signal via the second line. If the signal is present, the interlock loop is closed and the system can safely switch on. Through the monitoring presented here, material costs and production costs can be reduced and EMC problems due to, for example, HV / LV coupling at the header from HV potential to interlock and thus to the NV electronics or the NV cable set can be avoided.

The approach presented here results in a savings potential due to the omission of a line. Furthermore, there is a further potential savings by eliminating the twist of the lines.

At the HV header, the second interlock line for a case termination is connected directly to the shield connection to the switch box housing. Thus, the interlock circuit is closed via the already existing connection of the NV electronics with the switch box housing. The existing HV mating connector can still be used.

The material costs by eliminating the second Interlockleitung and the necessary twisting of the lines are reduced.

The approach presented here can also be used for several to be monitored HV plug-in systems on the same HV switch box.

In the approach presented here, the interlock at the HV header is changed so that the second interlock line is connected directly to the shield terminal on the switch box housing. Thus, the interlock circuit is closed via the already existing connection of the NV electronics with the switch box housing. The HV mating connector does not need to be changed. The signal of the signal generator may have a certain shape or fundamental frequency, so that the signal detector recognizes it clearly, as in the material of Schaltboxgehäuses other simpler signals (currents) and compensating eddy currents act, which induced by the shielding and potential equalization effect of the housing in it become.

2 shows a representation of a high-voltage connector 100 with a piezo element 200 according to an embodiment. The high-voltage connector 100 corresponds essentially to the high-voltage connector in 1 , In contrast, the counterpart has 122 here instead of an interlock bridge a printing structure 202 for deforming the piezoelectric element 200 on. The print structure 202 collides when inserting the counterpart 122 in the plug contour 120 with the piezo element 200 and deforms it from a rest position. The deformation causes the piezo element 200 placed under tension and an electrical voltage signal 204 generated.

In one embodiment, one pole of the piezoelectric element 200 with one of the ladder 114 electrically connected. The piezo element 200 is electrically insulating. Therefore, the high voltage is on the ladder 114 safely from the signal line at the other pole of the piezoelectric element 200 separated. The voltage signal 204 is superimposed on the high voltage voltage and can be within the component between the signal line and the conductor 114 be tapped.

In other words, an interlock is introduced using a piezoelectric element.

In the approach presented here, a piezo element is attached to the HV header, which is actuated when plugged HV mating connector. By actuating the piezoelectric element, an electrical voltage is generated depending on the material of the piezoelectric element. If the HV mating connector is inserted and acts with the force F on the piezo element, a defined voltage is impressed. Depending on the amount of voltage generated, this voltage can be evaluated by the NV electronics or the dlUS via just one cable. By an evaluation on dlUS the HV / LV coupling can be eliminated at the HV header, since the dlUS is arranged anyway in the "dirty" EMC range. The evaluation can be done via a signal detector analogous to the already existing voltage measurements. By integrating the piezo element into the HV header, the signal generator can be saved. Furthermore, it is possible to dispense with twisting the two interlock lines for EMC reasons.

The presented measuring principle is passive. In this case, no measurement signal is actively generated. Thus, the system is less error prone.

The HV header may have an interference contour around the piezo element into which only the mating contour of the HV mating connector fits. In the presented approach, the interlock bridge can be omitted.

The voltage can be led via a line to the dlUS, where the voltage is measured and evaluated. The dlUS communicates periodically with the NV electronics and can easily transfer this additional data via the CAN bus. In order to measure the voltage of the piezoelectric element, the piezoelectric element can be connected to the switchbox housing. This can easily be done via the existing HV header ground connection, since the shield of the external HV line is transferred via the HV mating connector to the HV header and then to the switch box housing. The dlUS (UI sensor, voltage-current sensor) is also connected to the housing of the switch box, so there is the same reference potential.

Furthermore, an alternative HV-Interlock is presented on the characteristic impedance.

In the approach presented here is determined by determining the characteristic impedance of existing lines / busbars. whether the HV mating connector is plugged. The additional lines from / to the signal generator / detector can be omitted. The determination of the plug-in state of the HV connector via the characteristic impedance of the line end. Depending on the plug state, there is another reflection behavior at the end of the line.

On material costs, for example, the Interlockleitungssatz, fasteners and associated holes can be saved. Furthermore, logistics and production costs can be saved because no Interlockleitungssatz must be plugged and fixed. Additional savings arise when the conventional interlock line set is divided again, and additional separation points can be omitted. Ferrite cores as an expensive countermeasure against EMC problems due to HV / LV coupling can also be dispensed with.

The approach presented here can be used on HV switch boxes, HV contacting system and dlUS. Manual assembly processes during final assembly as well as logistics and handling costs of high-voltage switch boxes are reduced by the omission of the interlock line set. In addition, the HV / LV coupling on the headers is eliminated.

For the approach presented here, a signal generator and a signal detector on HV electronics are used. With the existing shunts and the voltage tap in front of the main contactor "Plus", the dlUS measures the characteristic impedance across the busbars / conductors up to the HV header. The connection state is monitored using the reflection of the current and voltage waves at the line termination. If the mating connector is not plugged in, the cable end is open (ZL => ∞) and total reflection occurs (voltage doubling) and the reflection factor r is one.

If the mating connector is inserted, the line end is not open via the connected inverter, DC motor or similar and ZL (characteristic impedance) is finite. Ideally, ZL can be matched to the line impedance Zw and ZL = Zw (r = 0, nothing is reflected since all energy is absorbed in ZL).

The condition for the inserted HV mating connector on the HV header is thus ∞> ZL> Zw and thus 0 <r <1.

Since the devices described in detail above are embodiments, they can be modified in the usual way by those skilled in the art to a large extent without departing from the scope of the invention. In particular, the mechanical arrangements and the size ratios of the individual elements are selected by way of example only.

LIST OF REFERENCE NUMBERS

100

High-voltage connector

102

Interlockeinrichtung

103

body

104

joint geometry

106

breakthrough

108

wall

110

component

112

Implementing means

114

ladder

116

High-voltage line

118

umbrella

120

male profile

122

counterpart

124

Interlockbrücke

126

ground connection

200

piezo element

202

print Layout

204

voltage signal

Claims (4)

High-voltage connector (100) for a vehicle, in particular an electric vehicle, with - A base body (103) having a connection geometry (104) which is adapted to be inserted into an opening (106) through an electrically conductive wall (108) of a component (110) of an energy system of the vehicle; and - An integrated into the base body (103) implementing means (112) which is adapted to at least one electrical conductor (114) of a high-voltage line (116) of the energy system electrically isolated through the opening (106) to lead, wherein the implementing means (112) a plug contour (120) embodied in the main body (103) and an interlock device (102) for detecting a connection state of the plug contour (120), wherein a fixed part of the interlock device (102) is integrated into the plug contour (120), wherein the interlock device ( 102) is adapted to generate a connection state-dependent electrical signal for an evaluation. High-voltage connector (100) according to Claim 1 in which an electrical pole of the interlock device (102) is electrically conductively connected to a ground connection (126) of the main body (103). High-voltage connector (100) according to one of the preceding claims, wherein the interlock device (102) has a piezoelectric element (200) integrated in the main body (103) for generating a connection state-dependent voltage signal (204). High-voltage connector (100) according to Claim 3 in which an electrical pole of the piezoelectric element (200) is electrically conductively connected to the conductor (114).

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