High-voltage plug for a high-voltage plug connection, and high-voltage plug connection for a busbar

Abstract

The invention relates to a high-voltage plug (1) for a high-voltage plug connection (2), comprising a connection portion (3), by means of which the high-voltage plug (1) can be electrically conductively connected to a conductor end (4). The high-voltage plug (1) is primarily characterised in that the high-voltage plug (1) has a clamping portion (5) with clamping webs (7) which are spaced apart from one another by means of slots (6), and the clamping portion (5) is or can be spread apart in the radial direction. A high-voltage plug connection is provided here, which prevents damage to and breakage of conductors during a relative movement of the connected components by allowing axial movement.

Description

[0001] High-voltage connector for a high-voltage plug connection, as well as a high-voltage plug connection for a busbar

[0002] The invention relates to a high-voltage connector for a high-voltage plug connection, a high-voltage plug connection for a busbar, a busbar with such a high-voltage plug connection, and a high-voltage component with such a busbar for a high-voltage system in a motor vehicle.

[0003] High-voltage components, such as electric drive motors, batteries, or converters, such as DC / DC converters or AC / DC converters, are integrated into a high-voltage system, for example, of a motor vehicle, using busbars in industrial practice. Such busbars comprise a busbar that is electrically connected to a plurality of conductor ends of the electrical high-voltage component. The busbar, in turn, is electrically connected to a high-voltage contact, which is, for example, welded to the busbar. At the end of the high-voltage contact opposite the high-voltage component, a connection section is formed, by means of which the high-voltage contact is connected to a high-voltage line of the high-voltage system.

[0004] Movements, such as vibrations during operation of a motor vehicle, can lead to relative movement between the high-voltage cable and the high-voltage component. This can cause damage, or in the worst case, failure, of the high-voltage contact or the high-voltage cable.

[0005] Proceeding from this, the present invention is based on the object of at least partially overcoming the disadvantages known from the prior art. The features of the invention arise from the independent claims, for which advantageous embodiments are shown in the dependent claims. The features of the claims can be combined in any technically expedient manner, wherein the explanations from the following description as well as features from the figures, which comprise supplementary embodiments of the invention, can also be consulted for this purpose. The invention relates to a high-voltage connector for a high-voltage plug connection, having a connection section by means of which the high-voltage connector can be electrically connected to a conductor end.

[0006] The high-voltage connector is primarily characterized in that the high-voltage connector has a clamping section with clamping webs spaced apart from one another by means of slots, and the clamping section is spread or can be spread in the radial direction.

[0007] In the following, reference is made to a cylinder axis of the respective components, which are preferably at least partially rotationally symmetrical, when the axial direction, radial direction, or circumferential direction and corresponding terms are used without explicit indication to the contrary. Ordinal numbers used in the preceding and following descriptions serve only to clearly distinguish them and do not reflect an order or ranking of the designated components. An ordinal number greater than one does not necessarily require the presence of another such component.

[0008] A high-voltage connector is proposed here. Such a high-voltage connector is designed for use in a high-voltage connector. Such a high-voltage connector is designed to electrically integrate a high-voltage component into a high-voltage system, preferably in a motor vehicle.

[0009] For this purpose, the high-voltage connectors are preferably electrically connectable to a busbar of a busbar. Conductor ends of an electrical component of the high-voltage component are in turn electrically connected to the busbar or fastened thereto. Such a high-voltage component is, for example, an electric drive motor, a converter, for example a DC / DC converter or AC / DC converter, and / or a high-voltage battery. For example, a corresponding electrical component is the stator of the electric drive motor. The high-voltage connector has a connecting section by means of which the high-voltage connector can be electrically connected to a conductor end. For example, the connecting section can be mechanically and electrically connected to at least one conductor end, preferably to a plurality of conductor ends, or fastened to these, preferably by means of the busbar as described above.Alternatively, the connecting section can be electrically connected directly to the conductor end and mechanically fastened to it.

[0010] The high-voltage connector has a clamping section. The clamping section is designed to be inserted along an axial direction into an outer part, i.e., a complementary counterpart of the high-voltage plug connection to the high-voltage connector, and to be held therein by a radially acting clamping force. The clamping section preferably has a substantially cylindrical basic shape. The clamping section has a plurality of clamping webs. The clamping webs are arranged along the circumferential direction, preferably equidistant from one another, and spaced from one another by slots. The clamping webs are preferably arranged parallel to one another and to the axial direction. The axial direction is accordingly arranged parallel to an insertion direction of the high-voltage connector, preferably the cylinder axis of the high-voltage connector.

[0011] The clamping section is spread or expandable along the radial direction. For example, the clamping section is compressed along the axial direction to provide radial expansion. The clamping webs bend radially outward, thus expanding the circumference of the clamping section. Preferably, the clamping webs bend radially outward from the basic cylindrical shape of the clamping section. In other words, the clamping section has the shape of a curved, cylindrical cage.

[0012] By means of the spread or curved clamping section proposed here, a defined electrical contact and, at the same time, a movable axial fixation of the high-voltage connector in the outer part can be implemented. In other words, a defined electrical contact between the high-voltage connector and the outer part is provided by the radial compression of the clamping webs against the inner wall of the connector receptacle. For example, in an assembled state, the clamping webs are pressed radially against an inner wall of the outer part. For example, when the high-voltage connector is inserted, the clamping webs are elastically deformed radially inward, i.e., they are bent back slightly from their spread state. Thus, by means of the elastic restoring force, a radially acting contact force can be provided against the inner wall of the outer part. In the axial direction, the high-voltage connector is thus held, for example, by the frictional force acting orthogonally to the contact force.Thus, the high-voltage connector is held in place, against friction, along the axial direction within the outer part while still maintaining a defined electrical contact with it. This prevents, for example, cable breakages due to relative movement between different components.

[0013] It is further proposed in an advantageous embodiment of the high-voltage connector that the connecting section of the high-voltage connector is designed to be electrically conductively connected to a busbar and / or a conductor end; preferably, the connecting section is a welding section, which is preferably pressed and / or has a welding eyelet.

[0014] According to this embodiment, the high-voltage connector is designed to be electrically connected to a busbar and / or a conductor end by means of the connecting section. The high-voltage connector is electrically and mechanically attached to the busbar and / or the conductor end.

[0015] The connecting section is preferably a welded section and, in an assembled state, is welded to the busbar and / or the conductor end. For example, the cylindrical or hollow cylindrical shape of the high-voltage connector is pressed into a flat section and / or has a weldable eyelet, for example, a stamped one.

[0016] According to a further aspect, a high-voltage plug connection for a busbar is proposed, comprising

[0017] - a high-voltage connector according to an embodiment as described above; and

[0018] - an outer part with a cylindrical plug receptacle, wherein the high-voltage plug is arranged at least with the clamping section in the plug receptacle and the clamping webs are pressed radially outwards against an inner wall of the plug receptacle.

[0019] A high-voltage connector for a busbar is proposed here. As already explained, such a high-voltage connector is designed to electrically integrate a high-voltage component into a high-voltage system, preferably of a motor vehicle. In this regard, reference is made to the above description. The high-voltage connector comprises a high-voltage connector and an outer part.

[0020] The high-voltage plug is designed according to the above description.

[0021] The outer part has a cylindrical connector receptacle. The outer part is the complementary counterpart to the high-voltage connector, i.e., a female part into which the high-voltage connector is inserted in the axial direction. For example, the connector receptacle is made of a material with higher electrical conductivity than the rest of the outer part. Alternatively, the connector receptacle, which is cylindrical at least on the inside, is formed monolithically with the rest of the outer part. For example, the connector receptacle and / or the outer part are also cylindrical on the outside.

[0022] The high-voltage connector is therefore arranged in the connector receptacle with at least the clamping section. For this purpose, the high-voltage connector is inserted into the connector receptacle along the axial direction during assembly. The connector receptacle has a cylindrical inner wall. The clamping bars are in contact with this inner wall and are pressed against it from the radial inside to the radial outside, as already explained above. Thus, the high-voltage connector is mounted in the connector receptacle so that it can move axially.

[0023] Preferably, the clamping webs are designed in their radial extent and material thickness such that a sufficient frictional force acting in the axial direction is provided between the outer part and the high-voltage plug in order to prevent an unintentional movement of the high-voltage plug out of the outer part, but to enable a relative movement between the outer part and the high-voltage plug in the event of a relative movement between a high-voltage cable connected to the outer part and the high-voltage component.

[0024] It is further proposed in an advantageous embodiment of the high-voltage plug connection that the high-voltage plug is arranged with an axial play in the plug receptacle.

[0025] According to this embodiment, axial play is now arranged between the connector receptacle and the high-voltage connector. This ensures that an axial relative movement can occur between the outer part and the high-voltage connector without the high-voltage connector being displaced from the outer part. In other words, the connector receptacle is designed to be at least long enough along the axial direction that the high-voltage connector, with the highest point of the curvature exhibited by the clamping section before being inserted into the outer part, will not leave the connector receptacle during an expected relative movement between the outer part and the high-voltage connector.

[0026] It is further proposed in an advantageous embodiment of the high-voltage plug connection that the outer part has a connection means for a high-voltage line, preferably a thread for a screw.

[0027] The outer part can be connected to a high-voltage line by means of a connecting means, or can be mechanically and electrically secured to it. Such a high-voltage line is preferably an electrical high-voltage line, by means of which current is conducted to or from the corresponding high-voltage component, for example, to supply it with a high-voltage voltage.

[0028] The connection means is, for example, a thread for receiving a screw fastening. The connection means is preferably arranged at an axial end of the outer part, which is arranged opposite a receiving opening for the plug receptacle. In an advantageous embodiment of the high-voltage plug connection, it is further proposed that the high-voltage plug connection has an axially acting spring between the outer part and the high-voltage plug.

[0029] According to this embodiment, the high-voltage plug connection further comprises an axially acting spring. For example, the spring is a compression spring or a tension spring. For example, the spring is arranged on an end face axially opposite the receiving opening, i.e., between a front wall of the plug receptacle and the high-voltage plug. The corresponding front wall of the plug receptacle is also referred to as a stop. Alternatively or additionally, such a spring is attached to the axial end of the receiving opening in the plug receptacle.

[0030] It is further proposed in an advantageous embodiment of the high-voltage plug connection that the high-voltage plug connection has an axial securing means which prevents the high-voltage plug from moving out of the outer part.

[0031] Such an axial locking device is, for example, a retaining ring. Alternatively or additionally, the axial end of the outer part, which forms the receiving opening, is folded radially inward so that the diameter of the receiving opening is smaller than that of the plug receptacle.

[0032] According to a further aspect, a busbar is proposed, comprising at least the following components:

[0033] - a high-voltage plug connection according to an embodiment as described above;

[0034] - a busbar in electrical contact with the high-voltage connector; and

[0035] - a sheath that partially surrounds the high-voltage plug connection.

[0036] A busbar is proposed here. Such a busbar is designed to electrically connect a high-voltage component of a high-voltage system to a high-voltage line of the high-voltage system. The busbar comprises a high-voltage plug connection, a busbar, and a sheath. The high-voltage plug connection is designed according to the above description, to which reference is therefore made.

[0037] The busbar is electrically and mechanically connected to the high-voltage plug connection, preferably to the connection section of the high-voltage plug. The high-voltage plug and the busbar are preferably welded together by means of the connection section. The busbar is designed to electrically connect at least one, preferably a plurality of, conductor ends of the high-voltage component to the high-voltage plug connection. For example, the conductor ends are clamped or welded into the busbar. For example, all conductor ends connected to the busbar are the conductor ends of a common phase of the high-voltage component, for example, the conductor ends of a phase of stator windings of an electric drive machine.

[0038] The sheath surrounds the high-voltage connector such that the connection means of the outer part remains accessible from the outside. The sheath is preferably arranged such that the outer part protrudes from the sheath in sections on a side facing away from the high-voltage component. The sheath is preferably a plastic sheath; particularly preferably, it is molded around the high-voltage connector, more preferably injection-molded. The busbar is preferably mechanically fixed and insulated to the high-voltage component, for example, a housing of the high-voltage component, by means of the sheath.

[0039] For example, such a sheath comprises a plurality of high-voltage plug connections, for example one high-voltage plug connection per phase of the high-voltage component.

[0040] It is further proposed in an advantageous embodiment of the busbar that the busbar has a rotation lock by means of which the outer part is connected to the casing in a rotationally fixed manner.

[0041] Here, it is proposed that the busbar further comprise an anti-rotation device. The anti-rotation device preferably comprises at least a first part on the outer part and a complementary second part on the casing, which engage with one another along the circumferential direction and thus prevent rotation of the outer part relative to the casing. For example, one of the two parts is a groove or recess, and the other of the two parts is a complementary web or projection. For example, the casing forms one or more webs, and the outer part a corresponding number of complementary grooves. For example, the two parts of the anti-rotation device are pushed axially into one another during assembly.

[0042] According to a further aspect, a high-voltage component for a high-voltage system in a motor vehicle is proposed, comprising at least the following components:

[0043] - a busbar according to an embodiment as described above; and

[0044] - an electrical component having a plurality of electrical conductor ends; wherein the plurality of electrical conductor ends are electrically connected to the busbar of the busbar.

[0045] A high-voltage component for a high-voltage system in a motor vehicle is proposed here. Such a high-voltage system is preferably intended to supply a traction motor, i.e., an electric drive motor, in a purely electric motor vehicle (BEV [Battery Electric Vehicle]) or a hybrid vehicle with electrical power for driving the motor vehicle.

[0046] The busbar is designed according to the above description, to which reference is therefore made.

[0047] The electrical component has a plurality of electrical conductor ends. Accordingly, the electrical component is a current-carrying component of the high-voltage component, which is integrated into the high-voltage system by means of the conductor ends. Such an electrical component is preferably the stator or the stator windings of an electric drive motor. Alternatively or additionally, such an electrical component is a set of battery cells or power electronics of a high-voltage battery or a circuit of a converter, for example a DC / DC converter or AC / DC converter. The conductor ends are, as already explained above, electrically connected to a high-voltage line by means of the busbar.

[0048] The invention described above is explained in detail below against the relevant technical background with reference to the accompanying drawings, which show preferred embodiments. The invention is in no way limited by the purely schematic drawings, whereby it should be noted that the drawings are not to scale and are not suitable for defining proportions. It is shown in

[0049] Fig. 1 : a high-voltage plug connection with axial play in a cross-sectional view;

[0050] Fig. 2: a high-voltage connector according to Fig. 1 in a perspective view;

[0051] Fig. 3: an outer part of the high-voltage plug connection according to Fig. 3 in a perspective sectional view;

[0052] Fig. 4: a high-voltage plug connection with a sheathing section in a perspective view; and

[0053] Fig. 5: a stator of an electric drive machine with a high-voltage plug connection according to Fig. 1 in a perspective view.

[0054] Fig. 1 shows a cross-sectional view of a high-voltage plug connection 2 with axial play. The high-voltage plug connection 2 comprises a high-voltage plug 1 and an outer part 10. Both the high-voltage plug 1 and the outer part 10 are essentially cylindrical and arranged coaxially to one another, i.e., parallel to the axial direction 25. The axial direction 25 is arranged parallel to the cylinder axis or the insertion direction of the high-voltage plug 1 into the outer part 10.

[0055] The high-voltage connector 1 is arranged in a connector receptacle 11 of the outer part 10. The connector receptacle 11 extends from a first end 21 of the outer part 10 to a stop 23. At the first end 21, the outer part 10 forms a receiving opening 24 through which the high-voltage connector 1 was inserted into the outer part 10 during assembly. As shown, the outer part 10 is folded radially inward at the first end 21, i.e. in the region of the receiving opening 24, in order to form a securing means 15 and to prevent the high-voltage connector 1 from undesired movement out of the outer part 10. Alternatively, such axial securing against movement out is not necessary and the connector receptacle 11 merges into the receiving opening 24 with a constant diameter.

[0056] At an end 22 opposite the first end 21 along the axial direction 25, the outer part 10 has a connecting means 13 designed to electrically and mechanically connect a high-voltage cable (not shown here) to the high-voltage plug connection 2. As shown, the connecting means 13 is a thread 14 or a threaded hole, so that the high-voltage cable can be fastened by means of a screw.

[0057] The high-voltage connector 1 has a clamping section 5 and a connecting section 3. The clamping section 5 is arranged in the connector receptacle 11. The clamping section 5 comprises a plurality of clamping webs 7, six as shown, which are spaced apart from one another by slots 6 along the circumferential direction 27 (see Fig. 3). The clamping webs 7 are spread apart, i.e., bent outward in the radial direction 26.

[0058] The clamping section 5 preferably has a diameter which, in a relaxed state, i.e. before the high-voltage plug 1 is inserted into the outer part 10, is at least as large, preferably larger, than the diameter of the inner wall 12 of the plug receptacle 11. The clamping section 5 is therefore preferably compressed in the radial direction during insertion and, due to its elastic restoring force, generates a radially acting contact force against the inner wall 12 of the plug receptacle 11. The remaining high-voltage plug 1 correspondingly has a smaller diameter than the plug receptacle 11. The clamping section 5 thus forms a contact area 28 with the inner wall 12 of the plug receptacle 11, which axially fixes the high-voltage plug 1 by means of friction.This frictional force, or the contact force that causes the frictional force, is designed to enable axial movement between the high-voltage connector 1 and the outer part 10 to prevent cable breakage and damage. Along the axial direction 25, the connector receptacle 11 is designed to be longer than the distance between the axial outer part end of the high-voltage connector 1 and the contact area 28. In one exemplary embodiment (not shown here), for example, a spring is arranged axially between the outer part 10 and the high-voltage connector 1.

[0059] On the component side, the high-voltage connector 1 has a connection section 3.

[0060] The connecting section 3 is formed, for example, by pressing the cylindrical end of the high-voltage connector 1. For example, the connecting section 3 is designed to be welded to a busbar 8 of a busbar 9 (see Fig. 5).

[0061] Fig. 2 shows the high-voltage connector 1 according to Fig. 1 in a perspective view. In this respect, reference is made to the above description.

[0062] In Fig. 3, the outer part 10 of the high-voltage plug connector 2 according to Fig. 3 is shown in a perspective sectional view. The plug receptacle 11 is formed by a sleeve 29, which is inserted into the outer part 10. The sleeve 29 has a lower electrical resistance or a higher electrical conductivity than the section of the outer part 10 surrounding the sleeve 29.

[0063] Fig. 4 shows a perspective view of a high-voltage plug connector 2 with a sheathing section. The sheathing section shown is a section of the sheathing 16 in which a plug connector is arranged. The high-voltage connector 1 extends through the sheathing 16 in the axial direction 25 and is connected at a lower end to conductor ends 4 of a high-voltage component 18 (not shown here). The outer part 10 of the high-voltage plug connector 2 is rotationally fixed to the high-voltage component 18 (not shown here) by means of a rotation lock 17 of the sheathing 16.

[0064] For this purpose, the rotation lock 17 has two webs 32 and the outer part 10 has two complementary grooves 31. The webs 32 engage with the complementary grooves 31 in order to prevent rotation, for example when screwing the high-voltage cable to the outer part 10 by means of the connecting means 13.

[0065] In Fig. 5, a stator 30 of an electric drive machine with a high-voltage plug connection 2 according to Fig. 1 is shown in a perspective view.

[0066] The stator 30 has stator windings 20. The stator windings 20 are three-phase. The stator 30 has a plurality of conductor ends 4 for each phase.

[0067] The conductor ends 4 of a phase converge in a busbar 8 of a busbar 9. The busbar 8 is welded to the high-voltage connector 1 of the corresponding busbar 9 or the corresponding phase by means of the connecting section 3 and is thus electrically connected to it.

[0068] The connecting means 13 of the high-voltage plug connection 2 point away from the high-voltage component 18, i.e. here the stator 30 of the electric drive machine, so that an electrical high-voltage cable (not shown here) can be connected to it.

[0069] A rotor (not shown here for clarity) is arranged in the stator 30. The rotor has permanent magnets that generate a rotor magnetic field. When the stator windings 20 are energized via the high-voltage line, a stator magnetic field is generated, which interacts with the rotor magnetic field to generate torque.

[0070] In an alternative embodiment (not shown here), the high-voltage component 18 on which the high-voltage plug connections 2 are arranged is, for example, a converter, preferably of a high-voltage system of a motor vehicle, for example a DC / DC converter and / or an AC / DC converter.

[0071] Here, a high-voltage connector is proposed which, through axial movement, prevents damage and breakage to conductors during relative movement of the connected components.

[0072] High-voltage plug High-voltage plug connection

[0073] Connection section conductor end clamping section slot

[0074] Terminal bar busbar

[0075] Outer part plug socket inner wall

[0076] Connecting means Thread Securing means Sheath Anti-rotation device High-voltage component Component

[0077] Stator windings first end second end stop receiving opening axial direction radial direction circumferential direction contact area

[0078] sleeve

[0079] stator

[0080] Nut

[0081] web

Claims

Patent claims 1. High-voltage plug (1) for a high-voltage plug connection (2), comprising a connecting section (3) by means of which the high-voltage plug (1) can be electrically connected to a conductor end (4), characterized in that the high-voltage plug (1) has a clamping section (5) with clamping webs (7) spaced apart from one another by means of slots (6), and the clamping section (5) is or can be spread apart in the radial direction.

2. High-voltage plug (1) according to claim 1, wherein the connecting section (3) of the high-voltage plug (1) is designed to be electrically conductively connected to a busbar (8) and / or a conductor end (4), preferably the connecting section (3) is a welding section, which is preferably pressed and / or has a welding eyelet.

3. High-voltage plug connection (2) for a busbar (9), comprising - a high-voltage plug (1) according to claim 1 or claim 2; and - an outer part (10) with a cylindrical plug receptacle (11), wherein the high-voltage plug (1) is arranged at least with the clamping section (5) in the plug receptacle (11) and the clamping webs (7) are pressed radially outwards against an inner wall (12) of the plug receptacle (11).

4. High-voltage plug connection (2) according to claim 3, wherein the high-voltage plug (1) is arranged with an axial play in the plug receptacle (11).

5. High-voltage plug connection (2) according to claim 3 or claim 4, wherein the outer part (10) has a connection means (13) for a high-voltage line, preferably a thread (14) for a screw.

6. High-voltage plug connection (2) according to one of claim 3 to claim 5, wherein the high-voltage plug connection (2) has an axially acting spring between the outer part (10) and the high-voltage plug (1).

7. High-voltage plug connection (2) according to one of claim 3 to claim 6, wherein the high-voltage plug connection (2) has an axial securing means (15) which prevents the high-voltage plug (1) from moving out of the outer part (10).

8. Busbar (9), comprising at least the following components: - a high-voltage plug connection (2) according to one of claims 3 to 7; - a busbar (8) in electrical contact with the high-voltage plug connection (2); and - a sheath (16) partially surrounding the high-voltage plug connection (2).

9. Busbar (9) according to claim 8, wherein the busbar (9) has a rotation lock (17) by means of which the outer part (10) is connected to the casing (16) in a rotationally fixed manner.

10. High-voltage component (18) for a high-voltage system in a motor vehicle, comprising at least the following components: - a busbar (9) according to claim 8 or claim 9; and - an electrical component (19) having a plurality of electrical conductor ends (4); wherein the plurality of electrical conductor ends (4) are electrically connected to the busbar (8) of the busbar (9).

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