WO2010003507A1

WO2010003507A1 - High-voltage plug connection for motor vehicles

Info

Publication number: WO2010003507A1
Application number: PCT/EP2009/004269
Authority: WO
Inventors: Jürgen Engbring; Volker Albert; Christian Kuschnarew; Volker Hartmann; Peter Bucher
Original assignee: Leoni Bordnetz-Systeme Gmbh; Continental Automotive Gmbh
Priority date: 2008-06-17
Filing date: 2009-06-13
Publication date: 2010-01-14
Also published as: DE102008028785B4; DE102008028785A1

Abstract

The invention relates to a high-voltage plug connection (1), particularly for a motor vehicle having a number of high-voltage devices, for releaseably connecting a cable-side plug connector (4) connected to a power cable (19) and a device-side plug connector (2). A locking plug (7) can be inserted into a plug opening (10) of the device-side plug connector (2), wherein the locking plug (7) releaseably locks to the cable-side plug connector (4) contacting the device-side plug connector (2) in the plug connection by means of a locking element (35).

Description

description

High-voltage connector for motor vehicles

The invention relates to a high-voltage connector, in particular for a motor vehicle with high-voltage components, for the detachable electrical connection of a cable connected to a power cable side connector with a cable-side connector housing and a device-side held connector with a device-side connector housing.

An electric drive system of a drive configuration in a motor vehicle (hybrid drive, hybrid, electric or fuel cell vehicle) with at least one electric machine (synchronous or asynchronous machine) also has high-voltage components or units with voltages of currently already more than 300V (greater than 60V _D c greater than 25V _A c) on. These include in particular power actuators, in particular converters, power converters and / or converters, an electronic control unit or ECU (electronic controller unit).

The high-voltage network composed of the high-voltage devices and a high-voltage battery supplying them is usually protected by access protection in order to avoid a risk of injury when the high-voltage units carrying the high voltage are touched. For example, with the drive system switched off (and the machine still rotating), contact protection against a high voltage still available at the motor terminals of the electrical machine must be ensured.

Also, when releasing, for example, from DE 10 2006 047 039 A1 known connectors or contact connections and when opening the machine housing of the electrical machine or the device housing of the power actuators containing electronic control unit a drop in high voltage must be ensured in no time. Because of the high currents to be transmitted and the safety requirements with respect to the protection against contact and with regard to prescribed clearances and creepage distances, such high-voltage connectors have a particularly large design.

The invention has for its object to provide a suitable for the automotive sector, in particular space-saving and safe, high-voltage connector.

This object is achieved by the features of claim 1. Advantageous embodiments, developments and variants of the invention are the subject of the dependent claims.

For this purpose, a locking plug is provided as part of the high-voltage connector (HV connector), which can be inserted into a plug-in opening of the device-side stretch connector or its plug housing. In this mechanical connector, the locking plug locks the cable-side connector, for which purpose it has been previously contacted with the device-side connector electrically. A release of the power side HV connector is only possible after the locking connector is pulled.

The locking connector advantageously has at least one double function, namely the mechanical locking function of the two connectors and preferably an HVIL interrupt function (Hazardous Voltage Interlock Loop). For this purpose, as well as suitably in addition to the signal transmission, the locking plug HVIL or signal contact, so that in the connector also a releasable electrical connection with device-side signal or mating contacts is made. The device-side signal contacts are suitably arranged on a signal or filter board, which expediently also serves for (signal-side) shielding of the high-voltage connector.

The invention is based on the consideration that switching on the high voltage for the high-voltage devices from the joining process of the connector should be made dependent by a suitable, logical sequence of the joining order of the cable-side connector and the locking connector is specified. Particularly suitable for this purpose is a HV connector associated locking, sensor and / or signal connector, which is suitable already HVIL plug contacts of a particular in vehicles with electric drive system, eg. B. in hybrid vehicles, used as a safety measure high-voltage cut-off circuit (HVIL) includes.

A suitable joining order should specify that, on the one hand, the locking plug must be fitted to produce the high-performance plug connection and, as a result, the plug contact connection must be mechanically locked before the high voltage in the system is switched on. On the other hand, it is first necessary to release the locking plug, which is preferably provided with the HVIL functionality, before the high-performance HV plug connection can be released. This ensures that with each actuation of the HV connector, the high voltage in the system is always safely switched off electrically. In addition, a so-called CPA functionality (Connector Position Assurence) is met in addition to a reverse polarity protection against incorrect insertion of the plug and signal contacts. By integrating the HVIL, signal and / or sensor functionality into the locking connector, an additional HVIL, signal or sensor connector, eg. B. for a reed or Hall sensor omitted.

Both for the locking of the cable-side connector as well as to ensure that initially the power-conducting (HV) connector is done electrically and mechanically error-free, before the locking plug can be joined, mechanical means in the form of appropriately locking or locking elements in a simple manner be used.

The blocking element provided for locking the power-conducting plug-in or plug-in contact connection suitably protrudes into the device-side plug-in opening receiving the locking plug. In this area, the blocking element is preferably provided with a run-on slope, so that when joining the locking plug, the blocking element transversely to the direction of insertion, in particular against a spring force, is displaceable. On the side facing away from the run-up slope of the locking element, this has a locking cam or the like, which engages in a corresponding detent opening in the plug housing of the cable-side connector and thus reliably, but releasably locked in the joint connection with the device-side connector.

In an expedient development, the connector on a joint protection, which prevents the insertion of the locking connector when the connector of the cable-side connector is not made with the device-side connector. For this purpose, at least one locking element is suitably provided which blocks the plug-in opening provided for the locking plug when the plug-in connection is released and only then releases it when the cable-side and device-side plug-in connectors are joined together.

In a suitable embodiment, the locking and Riegeielemente part of a locking unit with a web or grid-like latch housing. In this is a bending spring in the form of a suitably forked punched spring plate, the spring elements formed by the fork tines interact with the locking and locking elements.

For the highest possible degree of prefabrication in the context of assembly of the HV plug connection according to the invention, the device-side plug housing has molded latching hooks. As a result, the device-side plug contact with the intended device housing of the corresponding high-voltage component in the course of a pre-assembly expediently be locked once. For this purpose, the device-side plug housing is suitably guided through a corresponding passage opening of the device into its interior, where it is contacted as intended and locked in the region of the opening edge of the passage opening. In this state, therefore, the corresponding device with the device-side connector is already pre-assembled.

Analogously, the locking plug on a connector housing integrally formed latching hook. For producing a releasable latching or snap connection with the cable-side plug housing is integrally formed on this a sealing collar, which surrounds in the Fügeverbidung the two connectors a aligned with the device-side insertion opening opening. The locking of the locking plug with the cable-side plug housing is thus advantageously carried out by a corresponding latching connection in the region of the sealing collar.

The cable-side plug housing expediently has two housing components or parts. While the housing-side connector is protected against contact, encloses a housing part to protect the contact elements of the cable-side connector whose contact elements on all sides and closes them - with the exception of a required for contacting passage - virtually completely.

The other housing part is expediently electrically conductive or has at least one metallic connection plate or a metal sheet through which, for example, one, two or three high-voltage lines with, for example, 16 mm ² to 70 mm ² conductor cross-section are sealed. This housing part, which is expediently provided with gripping elements, also preferably has the required holding or guiding elements for the locking plug, suitably in the form of the sealing collar surrounding the passage and plug opening for the locking plug.

In the manufactured HV connector closes the cable-side plug housing - and in particular its metallic housing part - the device opening on the device-side connector facing away from the outside of the housing almost completely. As a result, it is initially achieved that the device-side connector does not need to be additionally shielded, since this already rests in the usually metallic device housing and therefore is already effectively shielded from this. This makes it possible to dispense with complex shielding parts.

The cable-side connector is provided in the region of the cable or line bushing by means of expediently a braided overall shield, which is directly connected to the metallic housing part of the cable-side plug-in housing. The overall screen mesh in turn is suitably surrounded by a shrink tube. The overall screen mesh, in contrast to a separate shielding of the individual lines of the cable, a reduction of the line spacing, which in turn leads to a reduction in the size of the entire HV connector. Due to the shielding by means of the overall screen mesh, the HV connector has particularly good EMC properties, which is particularly advantageous in the automotive sector (hybrid or electric drives).

The advantages achieved by the invention are in particular that with the HV connector according to the invention a locking plug is carried, which expediently in addition to the locking function has at least the HVIL function and preferably before disconnecting the high-performance HV connector, the high voltage of the high-voltage system switches off electronically. The power management of the HV connector is thus achieved stress-free.

The signal contact realized as a separate locking plug enables the integration of signal and control functions together with the locking and HVIL functionality into a single connector as a multi-pole, for example eight-pole plug connector. Since the locking plug can only be joined when the high-performance HV plug-in contact is inserted correctly and completely, the CPA functionality is also fulfilled. Thanks to the combination with the HVIL plug-in contact, this CPA functionality can be felt mechanically and visually during assembly, as well as being electrically or electronically checked.

By blocking the signal connector in previously unproven HV connector a high degree of security is achieved even in the event that not all cable or cable components are reliably protected against contact. Is on the inside of the device-side connector to the quiet In order to ensure a filter function, the EMC properties are further improved.

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

1 shows a longitudinal section of a plugged high-voltage connector with a device-side connector (right) and with a cable-side connector (left) and with a locking plug in plug-in connection with the device-side connector,

Fig. 2, the dissolved high-voltage connector in a representation according to

Fig. 1,

3 and 4 in a perspective exploded view of the cable-side connector and the locking connector with a view of the connector outside or on the respective connector face,

5 and 6 in a view of the mating face of the device-side plug and signal connectors the released or blocked plug opening for the locking plug,

7 is a perspective view of a rear view of the device-internal connector with inserted locking unit,

8 and 9 in plan view and bottom view of the locking unit with inserted bending spring and thereby acted upon blocking element for the connector lock and locking elements as joint protection of the locking connector.

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

As can be seen comparatively clearly from FIG. 2, the illustrated high-voltage connector (HV connector) 1 comprises a device-side connector 2 with a power or female contact 3 (female contact) and a cable-side connector 4 with a corresponding power or male contact 5 (Male -Contact). The HV connector 1 also includes a device-side signal or filter board 6 and a locking plug 7. The signal board 6 contains a number of signal and / or HVIL contacts (connection pins) 8 for the transmission of control signals or for HVIL interruption (Hazardous Voltage Interlock Loop). Signal).

The device-side connector 2 has a plug housing 9 with a plug-in opening 10 with the contacts or pins 8 arranged therein for contacting with corresponding contacts (contact sockets) of the locking plug 7. By means of the plug-in housing 9 molded latching hooks 11 of the device-side signal connector 2 in the region of a passage opening 12 which is provided with an opening collar 13, locked with a partially visible device housing 14. The female contact 3 is in this mounting state of the connector 1 already inside the device housing 14, through the passage opening 12 of the connector 2 has previously been ushered in a pre-assembly or prefabrication step from the outside. This device housing 14 includes, for example, high-voltage components of a motor vehicle provided with an electric drive system, in particular a hybrid vehicle.

The cable-side connector 4 has a plug housing 15 with two housing parts 15a and 15b. The housing 15 has gripping elements 16 and essentially contains the plug contact 5. This housing is electrically connected, for example by means of a crimp or weld 17 with a power-conducting conductor or its conductor core 18 of a power cable 19 of the high-voltage system.

The housing part 15b which is fixedly connected to the housing part 15a, for example via a latch or the like, is expediently metallic. This housing part 15b has a sealing collar 20 as a receiving, guiding and sealing channel for the locking plug 7. In addition, in the region of a cable feedthrough, this housing part 15b has a dome-shaped feedthrough collar 21 for the or each of, for example, two or three conductors 18. In the region of the feed-through collar 21, a sealing element 22 is inserted into the plug-in housing. se 15 inserted between the housing parts 15a and 15b. In this area of the cable bushing, a shield surrounding all conductors 18 is provided in the form of a common overall screen mesh 23. This overall braided shield 23 in turn is encased by a protective tube, in particular a shrink tube 24, which is comparatively clearly evident from FIGS. 3 and 4.

As is comparatively clear from FIG. 1, the cable-side plug-in housing 15 fully surrounds the opening collar 13 of the device housing 14 in the case of a plug connection between the plug-in connectors 4 and 5. For this purpose, the housing part 15b of the plug housing 16 has a corresponding, closed housing collar 25, the opening contour of which corresponds to that of the opening collar 13 of the device housing 14; see. in particular FIGS. 4 and 5.

In the plug-in or joint connection shown in Fig. 1 is located between the opening collar 13 and the cable-side plug housing 15 on the housing collar 25 side facing away from a seal 26 a. Another seal 27 is located on the signal connector 7, so that it is sealed in the insertion position shown in Fig. 1 against the sealing collar 20. The signal connector 7 is latched in this plugging or joining position with the sealing collar 20 (FIGS. 3 and 4).

The locking plug 7 has a plug housing 28. A formed with a plug-in space 29 housing member 30 receives the sealing collar 20 of the plug housing 15. For the latching connection between the locking plug 7 and the cable-side connector 4 20 opposite locking elements 31 are integrally formed on the sealing collar, engage in the corresponding locking elements 32 on the connector housing 28 of the locking connector 7.

As can be seen from FIGS. 1, 2 and 5 and 6, the device-side connector 2 has a blocking element 35. This comprises a projecting into the plug opening 10 run-on slope 36 and on the opposite, the contacts 3 and 5 side facing a locking bolt or cam 37. This can also be designed with a run-on slope. The blocking element 35 cooperates with a spring element 38. Furthermore, a locking element 40 is inserted into the plug-in opening 10, which also interacts with the stamped spring plate designed as a common bending spring (FIGS. 8 and 9).

The locking element 40 is designed in the manner of a half-shell (FIGS. 4 and 6) and also has a run-on slope 41, which is formed on the actuating or locking end 42 of the locking element 40. With this locking end 42, the locking element 40 projects with the connectors 2.4 open, i. at completely pulled out of the device-side connector 2 connector 4 in a joining or contact space 43 of the device-side plug housing 9 inside. The clear width of this joining or receiving space 43 is adapted to the outer dimensions of the plug contact 5 enclosing the housing part 15 a of the cable-side plug-in contact 4.

By inserting the housing part 15a when joining the plug connectors 2,4, the locking element 40 is displaced transversely to the plugging or joining direction 45 against the force of the spring element 38 clearly visible in FIGS. 8 and 9, thus giving the previously blocked plug opening 10 of the device-side connector 2 free. Only in this state, in which the locking element 40 is displaced by means of the cable-side connector 4 and thus the HVIL joint protection for the locking plug 7 is released, this can be electrically connected to the device-side signal contacts 8. Therefore, this presupposes that previously the power-conducting connector between the cable-side connector 4 and the device-side connector 2 made mechanically correct and their contacts 3 and 5 are electrically connected to each other and connected to the female contact 3 device side busbar 46.

However, the power-side connector between the connectors 2 and 4 is electrically made only when the locking plug 7 is inserted and the electrical signal contact is made. In this plug-in connection of the locking plug 7 by means of the blocking element 35 locks the kabelseiti- gene connector 4, so that a reliable and secure mechanical HV lock is made. For this purpose, the locking plug 7 moves over the starting slope 36 of the blocking element 35 whose locking cam 37 into a corresponding recess 47 in the housing part 15a of the cable-side plug housing 15 (Fig. 1). The latching recesses 47 preferably also include contact springs for connecting the cable-side shielding to the device housing 14, ie for transmitting the shielding from the plug connector 4 to the device housing 14.

To release the connector, the locking plug 7 must first be pulled (counter to the insertion direction 45) to release the HV lock of the cable-side connector 4. Only then can this be pulled as well. After this time, d. H. Before the contactor or access protection underlying power-conducting connector 2.4 can be opened, the HV connector 1 and in particular the plug contacts 5 of the cable-side connector and due to the HVIL interruption and the associated security measure are already free of tension.

5 and 6 show the mating face of the device-side connector 2 with a view of the plug housing 9 practically completely closed, surrounding the opening collar 13 device or housing passage opening 12. Recognizable are two mutually edge-side locking elements 40 and the intermediate blocking element 35 in the In this case, Fig. 5 shows the fully unlocked by the locking elements 40 plug-in opening 10, while Fig. 6 shows the locking elements 40 to ensure the HVIL-Fügeschutzes not plugged connector 4 serving blocking position of the locking elements 40. In this joining protection, the bolt ends 42 protrude into the joining and contact space 43 of the device-side plug-in housing 9. Visible are also two laterally opposite latching elements 48, which correspond with correspondingly positioned latching elements 49 (Fig. 4) of the cable-side connector 4 and are releasably locked together in the joined HV connector with each other by means of the grip elements 16. 7 to 9 show a locking unit 50 with a web or grid-like latch housing 51, which is inserted into retaining rails 52 (FIG. 7) of the device-side plug-in housing 9 and latched there by means of snap hooks 53. In the latch housing 51, the spring element 38 is inserted and held by clamping cam 54. The fork-tooth-like spring ends 38a, 38b, 38c of the spring element 38 cooperate with the two locking elements 40 or with the blocking element 35 to produce the desired restoring force.

LIST OF REFERENCE NUMBERS

1 HV connector

2 device-side connector

3 female / female contact

4 cable-side connector

5 male / female contact

6 signal / filter board

7 locking connector

8 signal / HVIL contact

9 device-side plug housing

10 plug opening

11 snap hooks

12 passage opening

13 opening collar

14 device housing

15 cable-side plug housing

16 grip element

17 crimp / weld joint

18 conductors

19 power cables

20 sealing collars

21 implementing collar

22 sealing element

23 overall screen mesh

24 protective / shrink tubing

25 case collar

26 seal

27 seal

28 connector housing

29 plug-in space

30 housing element

31 locking element locking element

Locking element run-on slope locking bolt / cam bending spring / spring plate spring elementb spring elementc spring element

locking element

starting slope

bolt end

Fusion / Contact Space

transversely

plug-in direction

conductor rail

recess

locking element

locking unit

bolt housing

retaining rail

snap hooks

clamping cams

Claims

claims

1. high-voltage connector (1), in particular for a motor vehicle with a number of high-voltage devices, for releasable electrical connection of a cable connected to a power cable (19) cable-side connector (4) with a cable-side plug housing (15) and a device-side connector (2) with a device-side plug housing (9), characterized by a in a plug opening (10) of the device-side plug housing (9) insertable locking plug (7) in the connector with the device-side connector (2) contacted cable-side connector (4) by means of a blocking element (35) releasably locked.

2. Plug connection (1) according to claim 1, characterized in that the blocking element (35) into which the locking plug (7) receiving plug opening (10) protrudes and in the device-side plug housing (9) against the force of a spring element (38 c) is slidably held ,

3. Plug connection (1) according to claim 1 or 2, characterized in that the blocking element (35) in the insertion direction (45) of the locking plug (7) extending run-on slope (36) and opposite a locking cam (37), in the joint connection the two connectors (2,4) engages in a latching recess (47) in the plug housing (15) of the cable-side plug contact (4).

4. plug connection (1) according to one of claims 1 to 3, characterized in that the cable-side connector (4) in the joint connection with the device-side connector (2) a plugging the locking plug (7) into the insertion opening (10) releasing blocking protection.

5. Plug connection (1) according to claim 4, characterized in that the joining protection comprises at least one means of the cable-side connector (4) movable locking element (40).

6. Plug connection (1) according to claim 4 or 5, characterized by two edge of the plug opening (10) of the device-side plug housing (9) against the force of a spring element (38 a, 38 b) slidably guided locking elements (40).

7. Plug connection (1) according to any one of the preceding claims, characterized by a device with the device-side plug housing (9) latchable locking unit (50) with a in a latch housing (51) held fork-like bending spring (38) with one of the number of blocking and / or locking elements (35 or 40) corresponding number of prong-like spring elements (38a to 38c).

8. Plug connection (1) according to one of claims 1 to 7, characterized in that the device-side plug housing (9) integrally formed latching hooks (11) for producing a latching or snap connection of the device-side connector (2) with a device housing (14) in the area a passage opening (12) which serves for the implementation of the device-side connector (2).

9. Plug connection (1) according to one of claims 1 to 8, characterized in that the locking plug (7) has a plug housing (28) with integrally formed latching elements (32) for producing a releasable latching or snap connection with a sealing collar (20), which is designed to receive the locking plug (7) and is aligned with the plug-in opening (10) of the device-side plug-in housing (9).

10. Plug connection (1) according to one of claims 1 to 9, characterized in that the cable-side plug housing (15) has a number of contacts (5), in particular plug contacts, receiving the first housing part (15a) and a latched with this second housing part (15). 15b), and that the device-side plug housing (9) receives a corresponding number of mating contacts (3), in particular socket contacts.

11. Plug connection (1) according to claim 10, characterized in that the second housing part (15b) is formed electrically conductive and as complete as possible covering the passage opening (12) of the device housing (14).

12. Plug connection (1) according to claim 10 or 11, characterized in that the second housing part (15b) a housing collar (25) and handle, holding and / or guide elements (16,20,31) for the locking plug (7) having.

13. Plug connection (1) according to one of claims 1 to 12, characterized in that the plug housing (15) of the cable-side connector (4) in the region of a cable feedthrough (21) for the power cable (19) with a braided shield (23) for electrical Shielding is sheathed.

14. Plug connection (1) according to claim 13, characterized in that the braided shield (23) with a protective or shrink tubing (24) is sheathed.

15. Plug connection (1) according to one of claims 1 to 8, characterized in that the locking plug (7) comprises a functionality for signal transmission, as a sensor element and / or for HVIL interruption.