GB2598891A

GB2598891A - Method for automatically disconnecting an electric plug from an electric socket of a high voltage electric connection system

Info

Publication number: GB2598891A
Application number: GB2014143.8A
Authority: GB
Inventors: Nash Bryce
Original assignee: Daimler AG
Current assignee: Mercedes Benz Group AG
Priority date: 2020-09-09
Filing date: 2020-09-09
Publication date: 2022-03-23
Also published as: GB202014143D0

Abstract

A method suitable for automatically disconnecting an electric plug (12) from an electric socket (14) of a high voltage electric connection system (10) which is configured to connect an electric energy store of a vehicle with an electric network. The method comprises the steps of starting an air flow (34) through an air passage (26) provided in the electric plug (12), interrupting a first electric circuit (18) configured to detect at least one connection status, interrupting a second electric circuit (20) configured to provide connection related data, interrupting high voltage electric circuits (22, 24), and fully removing the electric plug (12) from the electric socket (14). The invention further relates to a high voltage electric connection system (10). The method may further comprise at least one coolant circuit (30, 32). The air flow may be deactivated while fully removing the plug (12) from the socket (14).

Description

METHOD FOR AUTOMATICALLY DISCONNECTING AN ELECTRIC PLUG FROM AN ELECTRIC SOCKET OF A HIGH VOLTAGE ELECTRIC CONNECTION SYSTEM

FIELD OF THE INVENTION

[0001] The invention relates to a method for automatically disconnecting an electric plug from an electric socket of a high voltage electric connection system, which is configured to connect an electric energy storage of a vehicle with an electric network. Moreover, the invention relates to a high voltage electric connection system which is configured to connect an electric energy storage of a vehicle with an electric network, wherein the high voltage electric connection system includes an electric plug and an electric socket, wherein the electric plug and the electric socket are designed to mate with each other in a connected status.

BACKGROUND INFORMATION

[0002] Generic methods and systems are known in the art. For instance, US 2019/0009680 Al discloses an apparatus that automates the connecting process between a primary connector and a secondary connector for charging an electric vehicle. The automated electrical connection apparatus employs a primary connector connection apparatus at a charge side and a secondary connector connection apparatus on a vehicle. In its non-use status, the primary connector at the charge side is flush with a surface of the ground. When the charging system is activated, the primary connector will extend up from the surface of the ground to engage the secondary connector on the vehicle. The automated electrical connection apparatus provides a means to align the corresponding electrical connection within primary and secondary apparatus to establish a connection between the primary at the charge side and the secondary connector on the vehicle. Once the charging cycle is terminated, the component parts of the charging systems will retract back to the flush position.

[0003] However, US 2019/0009680 Al does not provide a coolant connection to allow for unique thermal management of two mediums, or a heat exchange between the components on either side of the socket assembly or the high voltage electric connection system, respectively. This also does not provide the dedicated number of circuits that provide discrete features such as high voltage interlock, communication or temperature sensing, high voltage conductivity, potential equalization and the like, and also combine additional features from the same system elements such as e.g. alignment, position detection and/or the like.

[0004] Moreover, DE 10 2017 007 981 Al discloses a method and a system for cleaning of a charging device for charging a plug-in electric vehicle. However, this teaching does not provide a coolant connection to allow for unique thermal management of two mediums, or heat exchange between the components on either side of the socket assembly or the high voltage electric connection system, respectively.

[0005] Considering the above-mentioned state of the art, it is an object of the invention to improve a high voltage electric connection system such that thermal management can be achieved or improved.

SUMMARY OF THE INVENTION

[0006] According to the invention, a method and a system according to the independent claims are proposed.

[0007] Preferable embodiments can be derived from the features of the dependent claims.

[0008] With regard to a generic method, a method for automatically disconnecting an electric plug from an electric socket of a high voltage electric connection system is proposed which is configured to connect an electric energy storage of a vehicle with an electric network, wherein the method comprises the steps of: - starting air flow through an air passage provided in the electric plug; - interrupting a first electric circuit configured to detect at least one connection status; - interrupting a second electric circuit configured to provide connection related data; - interrupting high voltage electric circuits; and - fully removing the electric plug from the electric socket.

[0009] With regard to a high voltage electric connection system which is configured to connect an electric energy storage of a vehicle with an electric network, wherein the high voltage electric connection system includes an electric plug and an electric socket, wherein the electric plug and the electric socket are designed to mate with each other in a connected status, it is proposed that the high voltage electric connection system comprises: - a controllable pressurized air source; - a first electric circuit configured to detect at least one connection status; - a second electric circuit configured to provide connection related data; - at least two high power electric circuits having an air passage; and - a control apparatus configured to control movement of the plug with respect to the socket, wherein the control apparatus is further configured to initiate an action; - starting an air flow through an air passage provided in the electric plug; - interrupting the first electric circuit; - interrupting the second electric circuit; - interrupting the high voltage electric circuits; and - fully removing the electric plug from the electric socket.

[0010] The invention is comprised of a high-power electric connection system with an integrated pressurized air and, preferably, also liquid connections. The high-power electric connector system has a connector or plug that has a body that includes high voltage conductors, pressurized air connections, and, preferably, coolant connections to the vehicle. However, the electric plug does not need to be a part of the vehicle, but it may also be a part of a charging device to be connected with a vehicle, for example, for charging purposes or the like. In this regard, the plug may be a portion of a network. The network may be formed by the vehicle electric system. In alternate embodiments, the network may be formed by a charging station, a public power supply or the like.

[0011] The high-power electric plug provides the typical function of connecting high-power electrical systems that may additionally require liquid coolant. The connector or plug includes a novel concept of integrating e. g. pressurized air, a temperature sensor, and two position sensors that enable precise control over valve removal around the connection, an audible warning to living objects around the connection, and safety relevant indicators of the control systems in order to ensure safe and high quality connection and disconnection.

[0012] Generally, the system is comprised of preferably the following basic subsystems: - a controllable pressurized air source, - an electrical circuit to indicate the connector is in a completely closed position, - an electrical circuit to provide additional connector position information, which could include additional information such as a temperature sensor or communication signals, - a high power electrical connector with integrated air passages, - a coolant circuit to provide thermal management for electrical connection and components.

[0013] Preferably, between the high-power electric connector or plug and the pressurized air source, a valve may be present in order to control the flow of air to the high-power electric connector. Optionally, coolant hoses may be present in order to connect the high-power electric connector to a thermal management system on the vehicle with a self-closing fluid connection in order to achieve e.g. a "dry break"-connector.

[0014] The high-power electric connector or plug integrates at least two low power electrical circuits, preferably, used to provide position detection of the electrical connector or plug relative to a housing assembly. A typical high voltage connection may, for instance, include a single "high voltage interlock" (HVIL) connector for this function.

Additionally, a second circuit may be used for this high-power electric connection which can be used for a temperature sensor serving as a position indicator during connection and disconnection cycles, as well as providing temperature indication for control and diagnostic purposes and/or the like. By using both air and coolant connections in the assembly, the invention allows for unique thermal management properties, e.g. to heat, cool and rapidly cool as necessary for managing component temperature limits and to also remove ice, if necessary.

[0015] The normal operation of the high-power electrical connector or plug is automated with a control mechanism through all operational use cases. This automation combines a mechanical component which controls the connector position, such as a screw or cam or the like, operated by an electric board mechatronic actuator. This assembly is designed for frequent assembly/disassembly with a high cycle life expected. In case of failure of the automated actuation, the assembly can be disassembled with tools operated by a technician.

[0016] Typical use cases for this connection could include: A. Charging socket (vehicle connection to infrastructure) -This is valuable because a large volume of cooling or heating medium could be conditioned to target temperatures over a long period of time to reduce the power needed for thermal management and to use different energy sources when possible. The infrastructure could then provide vehicle heating and cooling during critical high-power charging so that the vehicle does not need high power equipment for thermal management. The air feature could also provide automated debris removal when an automated vehicle-to-grid connection is used.

B. Battery socket (energy storage to vehicle power distribution) -This is valuable if an automated battery exchange system is used to remove batteries from a vehicle. By combining many critical elements that are needed on a typical energy storage system into a single connector, this reduces the amount of automation necessary for battery exchanges, and also allows a highly optimized connection system for proper diagnostics and operation in a safety relevant system connection. The features present in the connector allow a robust connection and disconnection in typical use cases experienced in vehicle operation (hot, cold, freezing, dirty, etc.).

[0017] Further advantages, features, and details of the invention derive from the following description of preferred embodiments as well as from the drawings. The features and feature combinations previously mentioned in the description as well as the features and feature combinations mentioned in the following description of the figures and/or shown in the figures alone can be employed not only in the respectively indicated combination but also in any other combination or taken alone without leaving the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The drawings show in: [0019] Fig. 1 a schematic view of a fully seated target position of a high voltage electric connection system; [0020] Fig. 2 a schematic view as shown in Fig. 1, wherein an air flow through an air passage of an electric plug of the high voltage electric connection system according to Fig. 1 is started; [0021] Fig. 3 a schematic view as shown in Fig. 2, wherein a first electric circuit is interrupted; [0022] Fig. 4a schematic view as shown in Fig. 3, wherein a second electric circuit is interrupted; [0023] Fig. 5a schematic view as shown in Fig. 4, wherein a coolant circuit is interrupted; [0024] Fig. 6a schematic view as shown in Fig. 5, wherein high voltage electric circuits are interrupted; and [0025] Fig. 7a schematic view as shown in Fig. 6, wherein the electric plug is fully disconnected from the electric socket.

[0026] In the figures the same elements or elements having the same function are indicated by the same reference signs.

DETAILED DESCRIPTION

[0027] Fig. 1 shows in an exemplary view a first exemplary embodiment of the invention. As can be seen from Fig. 1, a high-voltage electric connection system 10 is provided which is configured to connect an electric energy storage of a vehicle with an electric network. The electric energy storage may be a battery of the vehicle, such as a lithiumion-battery or the like. Preferably, the electric energy storage is a high voltage battery. The term "high voltage" preferably conforms to the standard ECE R 100. For example, the high voltage may be more than about 60 V, for example, about 400 V, about 800 V, or the like. The vehicle is preferably an electric vehicle, such as a plug-in electric vehicle, a hybrid electric vehicle, or the like. The network may be an on-board high voltage electric network of the vehicle. However, the network may also be an electric network, which preferably can be a stationary electric network such as a public power supply. The electric network can comprise a charging station. The charging station may be connected with the vehicle via the high-voltage electric connection system 10. However, the high-voltage electric connection system 10 may also be used for a connecting system in order to allow the battery of the vehicle to be replaced or removed.

[0028] The high-voltage electric connection system 10 includes at least one electric plug 12 and at least one electric socket 14. The electric plug 12 and electric socket 14 are designed to mate with each other in a connected status, which is when the battery for the high voltage electric energy storage is placed in the vehicle and connected to its electrical system, or the vehicle is connected to a charging station or the like. In the present exemplary embodiment, the high-voltage electric connection system 10 is provided in the electric vehicle in order to couple the electric energy storage of the vehicle with the electric system of the vehicle. However, the invention is not limited to this application.

[0029] The high-voltage electric connection system 10 comprises a controllable pressurized air source 16. The pressurized air source 16 is provided in the vehicle. The vehicle and its components are not shown in the figures.

[0030] The plug 12 comprises for this purpose an air passage 26, which is in communication with the controllable pressurized air source 16. Fig. 1 shows the fully connected status of the electric plug 12 with the electric socket 14. The controllable pressurized air source 16 may be included by the vehicle.

[0031] Moreover, a first electric circuit 18 of the high-voltage electric connection system 10 is configured to detect at least one detection status. Presently in this embodiment, the fully connected status is detected. The first electric circuit 18 is connected with a control apparatus 28 of the vehicle so that the control apparatus 28 gets data with regard to the fully connected status of the electric plug 12 and the electric socket 14.

[0032] The high-voltage electric connection system 10 further comprises a second electric circuit 20 which is configured to provide connection related data. The second electric circuit 20 is also connected with the control apparatus 28. In the present embodiment, the related data may be a temperature of the high-voltage electric connection system 10, or the electric energy storage, or the like. However, further related data may be detected.

[0033] In an embodiment, the high-voltage electric connection system 10 comprises two high-power electric circuits 22, 24. The high-power electric circuits 22, 24 allow transferring high voltage electric energy between the electric network and the electric energy storage of the vehicle.

[0034] Further, the high-voltage electric connection system 10 comprises the control apparatus 28 which is located on the vehicle and which is configured to control movement of the plug 12 by way of initiating action with respect to the electric socket 25.

[0035] In the present embodiment, the high-voltage electric connection system 10 allows thermal management of the electric energy storage of the vehicle. In this regard, a temperature can be measured with regard to the connected status. It is further emphasized, that the high-voltage electric connection system 10 is designed to provide for automatically disconnecting the electric plug 12 from the electric socket 14. This will be further detailed below with regard to the use cases shown according to the Fig. 1 through 7. The normal operation of the high voltage electric connection system 10 is automated with a control mechanism using the control apparatus 28 that initiates action or movement through and between all the operational positions and sequences. This automation combines a mechanical component which controls the connector position, such as a screw or cam, operated by an electric mechatronic actuator (not shown in the figures). Manual operation in this regard can be reduced or avoided.

[0036] The basic operation concept as initiated and controlled by control apparatus 28 includes the following positions and sequences.

1. Fully seated (target position A) as shown in Fig. 1, normal operation In this position, the high voltage socket is in the fully seated, locked position. This provides sealing between the ambient environment and coolant circuit 30, 32 as well as the ambient environment and high voltage connection, and allows a minimum air evacuation path from ambient to the controlled truck air circuit. In this position, the high voltage interlock and second electrical circuit 22, 24 are also fully seated and close the relevant circuits. The coolant circuit 30, 32 allows normal coolant flow throughout the connector. The high voltage connectors allow full rated current.

2. Fully seated (target position A) as shown in Fig. 2, intended air flow 34 begins In this stage of operation, the connector 12 remains in the fully seated, locked position. The minimum air evacuation path described in step 1 above is still in place. The valve-controlled, on-board or off-board pressurized air source is enabled based on operation requirements. In the case of a desired cooling effect, this air flow 34 continues until the target temperature is obtained. In the case of debris clearing, the air flow 34 continues until the target debris clearing time is reached (based on calculated duty cycles since the previous cleaning cycle was executed). The controlled air flow 34 may also be used for an audible or tactile feature in order to alert living objects before further actions are taken. Depending on the target operation, the intended air flow 34 may continue in other stages of operation.

3. First target opening position (target position B) as shown in Fig. 3, broken electrical connection #1(10w voltage 1) At this stage, the connector 12 is not in a locked position. The connector has been mechanically unlocked so that it may begin to move. As the connector 12 moves away from the fully seated position, the first electrical connection (18) is disconnected. When this circuit is interrupted, this provides an indication to the control circuit 28 that the socket 14 is no longer in the seated position. This can be used to provide diagnostic functions, and provides an additional safety interlock to ensure that actions are taken at the system level to remove high voltage from the connector 12 in case this was not already done during normal operation of the system. In this stage of the process, air may continue to flow through the air evacuation path 26 for cooling, debris clearing, or tactile alert.

4. Second target opening position (target position C) as shown in Fig. 4, broken electrical connection #2 (low voltage 2) After the system control has confirmed that all safety checks have been met as expected, the next step is carried out to continue opening the socket until it reaches the second target opening position. In this position, the second electrical connection 20 (i.e. temperature sensor or communication signal) has been interrupted. This provides an additional feature for diagnostics and confirms that the connector position has continued to move. At this point, all safety features have been carried out to alert nearby living objects, control the connection temperature, and remove high voltage from the connection point. In this stage of the process, air may continue to flow through the air evacuation path for cooling, debris clearing, or tactile alert. In the event that not all safety checks are met as expected, the controlled opening process will be stopped and will not continue past this point. The socket would be returned to the fully seated position to ensure the highest safety level.

5. Third target opening position (target position D) as shown in Fig. 5, coolant connection is opened The system control 28 will continue to open the high voltage socket after the second target opening position. By the third target opening position, the self-closing coolant connection 30, 32 has been disconnected. In this stage of the process, air may continue to flow through the air evacuation path for cooling, debris clearing, or tactile alert. In the event that a fault in the system is detected after this point (coolant loss, electrical short circuit, isolation fault, etc.) the controlled opening process will be stopped and will not continue past this point. The socket would be returned to the fully seated position to ensure the highest safety level.

6. Fourth target opening position (target position E) as shown in Fig. 6, high voltage connection is opened After the coolant connection is broken and air flow 34 through the evacuation path has been stopped, the system control 28 will continue opening the high voltage socket to the fourth target opening position. At this point, the high voltage positive and negative connections 22, 24 have been disconnected. This can provide an additional position detection to the system for diagnostic and operation control. At this point, the only part of the high voltage socket that remains in contact is the alignment feature, which also acts as a potential equalization path between the male and female socket assemblies.

7 Fifth target opening (target position F) as shown in Fig. 7, fully disengaged socket After the fourth target opening position has been reached and only the potential equalizing alignment pin 36 is engaged, the system control 28 will continue to separate the two socket assemblies. The fifth target opening is a fully disengaged socket, with no connections remaining. This has a valve controlled air evacuation path which can be used for cooling, debris clearing, or tactile alert if necessary.

[0037] The embodiments are only for illustrative purposes and shall not be used to limit the scope of the invention.

Reference signs High-voltage electric connection system 12 Electric plug 14 Electric socket 16 Controllable pressurized air source 18 First electric circuit Second electric circuit 22 High-power electric circuit 24 High-power electric circuit Electric socket 26 Air passage 28 Control apparatus Coolant circuit 32 Coolant circuit 34 Air flow 36 Potential equalizing alignment pin

Claims

CLAIMS1. A method for automatically disconnecting an electric plug (12) from an electric socket (14) of a high voltage electric connection system (10) which is configured to connect an electric energy storage of a vehicle with an electric network, wherein the method comprises the steps of: -starting an air flow (34) through an air passage (26) provided in the electric plug (12); interrupting a first electric circuit (18) configured to detect at least one connection status; interrupting a second electric circuit (20) configured to provide connection related data; interrupting high voltage electric circuits (22, 24); and fully removing the electric plug (12) from the electric socket (14).
2. The method according to claim 1, further comprising a step of interrupting at least one coolant circuit (30, 32) before executing the step of interrupting the high voltage electric circuits (22, 24).
3. The method according to anyone of the preceding claims, further comprising the step of interrupting a coolant circuit (30, 32) after executing the step of interrupting the second electric circuit (20).
4. The method according to anyone of the preceding claims, further comprising the step of deactivating the air flow (34) together with fully removing the electric plug (12) from the electric socket (14).
5. A high voltage electric connection system (10) which is configured to connect an electric energy storage of a vehicle with an electric network, wherein the high voltage electric connection system (10) includes an electric plug (12) and an electric socket (14), wherein the electric plug (12) and the electric socket (14) are designed to mate with each other in a connected status, wherein the high voltage electric connection system (10) comprises: - a controllable pressurized air source (16); - a first electric circuit (18) configured to detect at least one connection status; - a second electric circuit (20) configured to provide connection related data; - at least two higher power electric circuits (22, 24) having an air passage (26); - and a control apparatus (28) configured to control movement of the plug (12) with respect to the socket (24), wherein the control apparatus (28) is further configured to initiate an action; - starting an air flow (34) through an air passage (26) provided in the electric plug (12); - interrupting the first electric circuit (18); - interrupting the second electric circuit (20); - interrupting the high voltage electric circuits (22, 24); and - fully removing the electric plug (12) from the electric socket (14).
6. The high voltage electric connection system according to claim 5, comprising at least one coolant circuit (30, 32), wherein the control apparatus (28) is further configured to initiate the action of interrupting the coolant circuit (30, 32) before interrupting the high voltage electric circuits (22, 24).
7. The high voltage electric connection system according to claim 5 or 6, wherein the control apparatus (28) is further configured to initiate the action of interrupting the coolant circuit (30, 32) after interrupting the second electric circuit (20).