GB2594321A

GB2594321A - Manual service disconnect

Info

Publication number: GB2594321A
Application number: GB2006010.9A
Authority: GB
Inventors: Burkett Roger; Stevens Alistair; R Bednarski Kris; Castro Maite
Original assignee: Eaton Intelligent Power Ltd
Current assignee: Eaton Intelligent Power Ltd
Priority date: 2020-04-24
Filing date: 2020-04-24
Publication date: 2021-10-27
Also published as: GB202006010D0

Abstract

A manual service disconnect 10 for opening and closing a high current fused path (eg for a car battery) comprises a socket assembly 12 and plug assembly 14. The socket has two or more fixed contacts 120 for electrically connecting with the high current fused path, one or more trigger contacts 124 and a receptacle 126. The plug comprises one or more high current connectors 140 and a pyromechanical separation device 142 positioned next to the connector. The current can be cut off by withdrawing the plug to a second position, or by a signal on the trigger contact causing the explosive to sever the link 140. Optional contacts 122 may detect when the plug has reached a third position so that power in the contacts may be cut off by a relay (32, Fig 2) before the link is removed. A pivotable handle (146, Fig 5) may be used to move the plug. As the explosive is in the plug it can be replaced by a new plug after it is triggered.

Description

MANUAL SERVICE DISCONNECT

TECHNICAL FIELD

This specification relates to a manual service disconnect.

BACKGROUND

A manual service disconnect or master switch disconnect (MSD) is provided to allow disconnecting a high current power circuit of a battery pack particularly for servicing the battery pack. An MSD usually comprises a fused electrical path between connectors for a battery pack and a load such as an electrical engine of an electrical or hybrid vehicle. Also; MSDs with a non-fused electrical path are available, which are provided for only a manual disconnecting without a circuit protection with a fuse. An MSD may also comprise a high voltage interlock (HVIL), which is provided for controlling operation of the high current power circuit.

1JS9509096B2 discloses an MSD for a battery system including a disconnect header configured to be mounted externally proximate to a battery pack. The disconnect is header includes a housing defining a receptacle, a high current terminal connector within the receptacle, a high voltage interlock loop (HVIL) connector within the receptacle and a control device terminal connector within the receptacle. A disconnect plug is removably coupled to the disconnect header. The disconnect plug has a high current fuse electrically connected to the high current terminal connector and a HVIL shunt terminal electrically connected to the HVIL connector. A current power control device is received in the receptacle. The current power control device is electrically connected to the control device terminal connector. The current power control device is exposed for servicing when the disconnect plug is removed from the disconnect header and the current power control device is inaccessible when the disconnect plug is coupled to the disconnect header

SUMMARY

This specification describes an MSD for opening and closing a high current fused path.

The MSD comprises a socket assembly comprising two or more fixed contacts for electrically connecting with the high current fused path, one or more trigger contacts and a receptacle; a plug assembly adapted to be attached to the receptacle of the socket assembly in a first and a second position and mant.tally releasable from the receptacle; wherein the plug assembly comprises one or more high current connectors and a pyromechanical separation device positioned next to the one or more high current connectors, wherein each of the high current connectors comprises at least two contacts; wherein the at least two contacts of each of the one or more high current connectors are electrically connected to the two or more fixed contacts only when the plug assembly is attached to the receptacle in the first position, and wherein the pyromechanical separation device is electrically connected to the one or more trigger contacts only 'when the plug assembly is attached to the receptacle in the first position. The MSD combines the functionality of a standard MSD with a pyromechanical switch. Due to the two-part design comprising a socket assembly and a plug assembly is removable from the plug assembly and housing the pyromechanical separation device; the plug assembly may easily be replaced after activation of the pyromechanical separation device. The MSD also may retain the safety of a manual total isolation of the MSD by removing the plug assembly from the socket assembly, which may interrupt a high current fused path in which the MSD is switched.

In embodiments, the socket assembly may comprise two or more HVIL contacts and the plug assembly may comprise one or more HVIL connectors; wherein the plug assembly is adapted to be attached to the receptacle of the socket assembly in a third position being an intermediate position between the first and second position, wherein the one or more high current connectors are also electrically connected to the two or more fixed contacts when the plug assembly is attached to the receptacle in the third position and the pyromechanical separation device is also electrically connected to the one or more trigger contacts when the plug assembly is attached to the receptacle in the third position, and wherein the one or more HVIL connectors are electrically connected to the two or more HVIL contacts only when the plug assembly is attached to the receptacle in the first position. The third position and the contacts and connectors may be provided for controlling a circuit breaker for interrupting the high current fused path and, thus, may implement a further security measure since the contacts of the circuit breaker may be closed via the HVIL only on the first position. The HVIL circuit may isolate a battery or high voltage circuit before the plug assembly is completely removed from the socket assembly of the MSD. This prevents the plug assembly pulled out of the socket assembly under load which would be dangerous The r HVIL connectors and contacts are therefore disconnect before the high current fused path is closed, and the HVIL connectors and contacts may be connected after or when the high current fused path is closed.

In embodiments, the plug assembly may comprise a handle provided for manually removing the plug assembly from the socket assembly and for moving the plug to assembly between the different positions. The handle may make handling of the plug assembly more comfortable, and particularly to move the plug assembly into the different positions. The handle may be pivotably fixed to the plug assembly. For example, different swiveled positions of the handle may move the plug assembly into the first, second or third position, particularly by means of respective guiding means comprised by and/or attached to the plug and/or socket assembly. Furthermore, the handle may be clarripable to the plug assembly in a provided position when the plug assembly is attached to the receptacle in the first position. In the first position, the provided position for clamping the handle to the plug assembly may be such that the handle is in a retracted position in which the MSD has a space-saving outer shape.

In further embodiments, the plug assembly may comprise a plug outer housing with means for attaching the handle and a plug inner housing adapted to be inserted in the plug outer housing, wherein the pyromechanical separation device is positioned between the inner and the outer plug housing. The outer and inner housings may be for example made of an electrically isolating material such as a plastic.

In yet further embodiments, the plug assembly may comprise one or more side clips provided for clipping the plug assembly to the socket assembly. The side clips may improve the fixation of the plug assembly to the socket assembly, which may be helpful in a harsh environment with vibrations such as in a vehicle and particularly avoid that the plug assembly separates itself from the socket assembly.

In yet further embodiments, the plug assembly may comprise one or more vent holes for a release of gasses generated by the pyromechanical separation device upon activation. The release of gasses may avoid a bloating of the MSD, particularly of the plug assembly, and damages of surrounding components, for example inside a vehicle.

In embodiments, the socket assembly may be designed to be attached to a battery package. Such an MSD may be for example mounted on a battery package particularly for application in electric vehicles.

In further embodiments, the socket assembly may comprise a socket outer housing with means for fixing the socket assembly to a structure and a socket inner housing adapted to be inserted in the socket outer housing, wherein the one or more fixed contacts are positioned between the inner and the outer socket housing.

In further embodiments, the MSD may comprise one or more indicators for identification of an activation of the pyromechanical separation device. Thus, an emergency case, which caused an activation of the pyromechanical separation device, may be more easily recognized by service personnel.

The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features and advantages will be apparent from the description and drawings, and from the claims.

DESCRIPTION OF DRAWINGS

Fig. 1 shows a schematic sectional representation of an embodiment of an MSD; Fig. 2 shows a circuit diagram of an embodiment of battery supply of an electric drive comprising an embodiment of an MSD; Fig; 3 shows an exploded perspective view of an embodiment of a socket assembly of an MSD; Fig. 4 shows an exploded perspective view of an embodiment of a plug assembly of the MSD of Fig. 3; and Fig. 5 A -C show an embodiment of the MSD with the plug assembly being in the first, third, and second position, respectively.

DETAILED DESCRIPTION

In the following, functionally similar or identical elements may have the same reference numerals. Absolute values are shown below by way of example only and should not be construed as limiting.

Fig 1 shows an MSD 10 comprising a socket assembly 12 and a plug assembly 14 separated from the socket assembly 12. Both assemblies 12, 14 are shown in a partial sectional representation for illustrative purpose to show the internal arrangement of components of the assemblies.

The socket assembly 12 comprises a socket basis 130 and a receptacle 126 for receiving the plug assembly 14. The socket basis 130 comprises fixed contacts 120, optional HVIL contacts 122 and a trigger contact 124. The fixed contacts 120 are is provided to be connected to a high current fused path into which the MSD 10 may be switched for emergency and controlled interruption. The optional HVIL contacts 122 are provided to establish a HVIL being controlled by the MSD 10. The trigger contact 123 is provided to control a pyromechanical separation device 142 comprised by the plug assembly 14.

The plug assembly 14 comprises in addition to the pyromechanical separation device 142 a high current connector 140 arranged under the pyromechanical separation device 142 such that upon activation of device 142 a miniature guillotine is propelled by a pyrotechnic charge to cut through the high current connector 140. The pyromechanical separation device 142 is activated by a pulse on the trigger contact 124, for example a current or voltage pulse, when the plug assembly 14 is completely attached to the socket assembly 12 in the receptacle 126 so that all contacts 120, 122, 124 are electrically connected to respective contacts and connectors of the plug assembly 14. An optional HVIL connector 144 may be also arranged within the plug assembly 14. The plug assembly 14 further comprises a hinged handle 146 for comfortably attaching the plug assembly 14 to the socket assembly 12 and removing it. The MSD 10 shown in Fig, 1 may be also implemented without the HVIL, i.e. without the optional HVIL. contacts 122 and the optional HVIL connector 144 Fig. 2 shows a circuit diagram of a battery supply circuitry of an electric or hybrid vehicle. A battery package 30 provides a power supply for an electric drive 34. A high current fused path 36 from the anode of the battery package 30 to the respective contact of the electric drive 34 is secured with an MSD 10. An optional circuit breaker 32 may be is provided as further security measure during servicing when the plug to assembly of the MSD 10 is separated from the socket assembly. The circuit breaker 32 may be controlled via a HVIL formed via the optional HVIL connector 144 being arranged within the plug assembly 14 and the optional HVIL contacts 122 being comprised in the socket basis 130. The HVIL comprises a source (not shown) for generating a control signal transmitted via the HVIL to a control input of the circuit is breaker 32. The attachment of the plug assembly of the MSD 10 in the re,ceptable 126 in a position in which the optional HVIL contacts 122 are contacted via the optional HVIL connector 144 closes the HVIL, thus, enabling the transmission of the control signal to the control input of the circuit breaker 32 via the HVIL so that the main contacts of the circuit breaker 32 may be closed, and the high current fused path 36 over these closed contacts is also dosed. The separation of the plug assembly of the MSD 10 from the socket assembly 12 interrupts the HVIL. via the optional HVIL. connector 144; thus causing the transmittal of the control signal for the circuit breaker 32 over the HVIL to close the contacts of the circuit breaker 32 to be interrupted, which causes a switching off of the circuit breaker 32 and opening of its contacts. The opening of the contacts of the circuit breaker 32 interrupts the high current fused path 36 so that the MSD 10 is isolated from the battery package 30.

The high current fused path 36 can also be interrupted by activating the pyromechanical separation device of the MSD 10; which cuts through the high current connector in the plug assembly of the MSD 10. The pyromechanical separation device may be activated by a trigger signal, which may be for example generated by an external device (not shown) such as a processor, which may be provided and configured to process a signal from a current monitor, an airbag sensor, a smoke detector, an overheating detector of the battery package 30 or another suitable sensor signal to generate the control signal. The processor may particularly generate a trigger signal if an overheating detector signals an overheating of the battery package 30, a smoke detector signals smoke possibly caused by a burning battery package 30, an airbag sensor signals a crash, and/or a current monitor signals an overcurrent situation on the high current fused path 36.

Fig. 3 shows a perspective exploded view of the socket assembly 12. As can be seen, two fixed contacts 120 are arranged between an inner housing pan 132 and an outer to housing part 128. The outer housing part 128 comprises at its bottom a socket basis with holes for screws and for the optional HVIL contacts 122. A rubber seal layer may be provided as bottom seal 136 to damp vibrations transferred from the structure, to which the socket assembly 12 is attached, to the 1\11SD 10. Both fixed contacts 120 can be electrically connected by the high current connector 140 arranged in the plug assembly 14, when the plug assembly 14 is fully attached to the socket assembly 12.

Fig. 4 shows a perspective exploded view of the plug assembly 14. The pyromechanical separation device 142 is positioned in an inner housing part 150, which is arranged within an outer housing part 148 of the plug assembly 14. A seal 152 may be inserted between the inner and outer housing parts 148, 150, for example to damp vibrations. The handle 146 is pivotably attached to the outer housing part 148.

The plug assembly 14 may be positioned on the socket assembly 12 in three different positions, as shown in Fig. 5: In a first position A, the plug assembly 14 is fully attached to the socket assembly 12 so that all electrical contacts between both assemblies 12, 14 are closed, particularly the fixed contacts 120 via the high current connector 140, the optional HVIL contacts 122 via the optional HVIL connector 144, and the trigger contact 124 to activate the pyromechanical separation device 142. In the first position A, the handle 146 may be pivoted around its rotation axis 147 in a position, in which a push button 134 may lock the handle 146.

In a third, middle position B. the plug assembly 14 is attached to the socket assembly 12, but not fully. In this position, only the fixed contacts 120 are closed via the high current connector 140, but the HVIL contacts 122 are open. Thus, in the third position B, the circuit breaker 32 (Fig. 2) is open since no signal via the HVIL contacts can be transmitted to close its contacts. In this position, the handle 146 is unlocked from the push button 134 and swiveled in 45° approximately.

In a second position C, the plug assembly 14 is attached to the socket assembly 12, but so far away from the socket base that all contacts are open. The handle 146 is swiveled in 90" approximately so that the plug assembly 14 can easily be removed 10 from the socket assembly 12.

Total travel of the plug assembly from the second to the first position may be for example about 10 millimeters, while the travel from the third to the first position may be about 6 millimeters.

The swiveling of the handle 146 may cause the movement of the plug assembly 14 on the receptacle of the socket assembly 12, for example by means of a guiding. The guiding may be for example designed so that the plug assembly 14 may only be attached to the receptacle of the socket assembly 12 when the handle 146 is swiveled about 90° (second position C), and that the plug assembly 14 may be moved downwards on the socket assembly 1210 the third and first position B, A by swiveling the handle 146 around the axis 147 from about 90° to about 0°. The swiveling of the handle 146 may cause the downward movement of the plug assembly 14 by the guiding. One or more stoppers may be provided at the socket assembly 12 to define a vertical and horizontal position of the plug assembly 14.

In normal operation, the handle 146 is brought into the first position A, and for servicing the handle 146 may be unlocked by pushing the button 134 and swiveling the handle 146 about 45" while moving the plug assembly 4 upwards away from the socket assembly 12 into the third position B, in which the HVIL contacts are opened so that the circuit breaker 32 (Ha. 2) interrupts the high power path from the battery package 30 to the electric drive 34. To remove the plug assembly 14, for example to replace the pyron-iechanical separation device after an activation, the handle 146 may be swiveled about further 45° to an approximately 90° position (second position C). Then, service personnel can remove the plug assembly 14 from the socket assembly 12 for particularly replacing a cut through high current connector and a pyromech,anical separation device of the plug assembly 14.

The above described embodiments of an MSD allow a tool free servicing, i.e. removing of a plug assembly for example after the pyromechanical separation device in the plug assembly was activated.

The herein disclosed and described MSD is particularly suitable for application in an electric or hybrid vehicle to interrupt a high current path from a battery package to an electric load such as an electric drive unit, wherein interruption may be caused in emergency cases by activating the pyromechanical separation device integrated in the plug assembly of the MSD or manually for servicing by swiveling the handle and lifting the plug assembly to move it upwards from the socket assembly to open HVIL contacts and interrupt the high current path.

Reference numerals manual service disconnect (MSD) 12 socket assembly fixed contact 122 high voltage interlock loop (HVIL) contact 124 trigger contact 126 receptacle 128 socket outer housing part socket basis 132 socket inner housing part 134 push button 136 bottom seal 138 screws 14 plug assembly high current connector 142 pymmechanical separation device 144 HVIL connector 146 handle 147 handle rotation axis 148 plug outer housing part 150 plug inner housing part 159 seal battery package 39 circuit breaker 34 electric drive 36 high current fused path

Claims

CLAIMS1. A manual service disconnect (10) for opening and closing a high current fused path comprising * a socket assembly (12) comprising two or more fixed contacts (120) for electrically connecting with the high current fused path, one or more trigger contacts (124) and a receptacle (126), * a plug assembly (14) adapted to be attached to the receptacle (126) of the socket assembly (12) in a first and a second position and manually releasable from the receptacle (126), * wherein the plug assembly (14) comprises one or more high current connectors (140) and a pyromechanical separation device (142) positioned next to the one or more high current connectors (140), wherein each of the high current connectors (140) comprises at least two contacts, * wherein the at least two contacts of each of the one or more high current connectors (140) are electrically connected to the two or more fixed contacts (120) only when the plug assembly (14) is attached to the receptacle (126) in the first position, and * wherein the pyromechanical separation device (142) is electrically connected to the one or more trigger contacts (124) only when the plug assembly (14) is attached to the receptacle (126) in the first position.
2 The manual service disconnect (10) of claim 1, wherein the socket assembly (12) comprises two or more high voltage interlock loop contacts (122) and the plug assembly (14) comprises one or more high voltage interlock loop connectors (144), wherein the plug assembly (14) is adapted to be attached to the receptacle (126) of the socket assembly (12) in a third position being an intermediate position between the first and second position, wherein the one or more high current connectors (140) are also electrically connected to the two or more fixed contacts (120) when the plug assembly (14) is attached to the receptacle (126) in the third position and the pyromechanical separation device (142) is also electrically connected to the one or more trigger contacts (124) when the plug assembly (14) is attached to the receptacle (126) in the third position, and wherein the one or more high voltage interlock loop connectors (144) are electrically connected to the two or more high voltage interlock loop contacts (122) only when the plug assembly (14) is attached to the receptacle (126) in the first position.
3. The manual service disconnect (10) of claim 1 or 2, wherein the plug assembly (14) comprises a handle (146) provided for manually removing the plug assembly to (14) from the socket assembly (12) and for moving the plug assembly (14) between the different positions.
4. The manual service disconnect (10) of claim 3, wherein the handle (146) is pivotably fixed (147) to the plug assembly.
The manual service disconnect (10) of claim 4, wherein the handle (146) is clampable to the plug assembly in a provided position when the plug assembly (14) is attached to the receptacle (126) in the first position
6. The manual service disconnect (10) of claim 3, 4 or 5, wherein the plug assembly (14) comprises a plug outer housing part (148) with means for attaching the handle (146) and a plug inner housing part (150) adapted to be inserted in the plug outer housing part (148), wherein the pyromechanical separation device (142) is positioned between the inner and the outer plug housing parts (148, 150).
7 The manual service disconnect (10) of any preceding claim, wherein the plug assembly (14) comprises one or more side clips provided for clipping the plug assembly (14) to the socket assembly (12).
8 The manual service disconnect (10) of any preceding claim, wherein the plug assembly (14) comprises one or more vent holes for a release of gasses generated by the pyromechanical separation device (142) upon activation.
9. The manual service disconnect (10) of any preceding claim, wherein the socket assembly (12) is designed to be attached to a battery package.
10. The manual service disconnect (10) of any preceding claim, wherein the socket assembly (12) comprises a socket outer housing part (128) with means (130) for fixing the socket assembly to a structure and a socket inner housing part (132) adapted to be inserted in the socket outer housing part (128), wherein the one or more fixed contacts (120) are positioned between the inner and the outer socket housing parts (128, 132).
11 The manual service disconnect (10) of any preceding claim, comprising one or more indicators for identification of an activation of the pyrornechanical separation device (142).