Electric wire assembly and motor vehicle

Abstract

The present disclosure relates to a wire assembly (10) for conducting a current from a charging socket (160) of a motor vehicle (100) to an energy storage device (150) of the motor vehicle (100), comprising: a direct current line (20) having two direct current single lines (21, 22) for conducting a direct current (DC) from a direct current interface (120) of the charging socket (160) to the energy storage device (150); the invention relates to a wire arrangement (10) for connecting an energy storage device (150) to a charging socket (160), and an AC wire (30) having a plurality of AC single wires (31) for conducting an AC power (AC) from an AC interface (130) of the charging socket (160) to the energy storage device (150), the wire arrangement (10) having an AC plug-in connection (33) that can be connected to the AC wire (30), the AC plug connection (33) is provided for electrically connecting the wire arrangement (10) to the AC interface (160) and / or to the energy storage device (150).

Description

Technical Field

[0001] The present disclosure relates to a cordset for directing electric current from a charging socket of a motor vehicle to an energy storage device of the motor vehicle. The present disclosure also relates to a motor vehicle. Background Art

[0002] Within the scope of the increasing need for environmental sustainability, advancing the transformation of mobility is a key aspect. For this and other reasons, the production and use of electric vehicles is a core component for achieving more sustainable mobility. A core component of an electric vehicle is the charging chain or charging unit, which leads from the energy storage device via a cordset to a charging socket. A charging station external to the vehicle can be connected to the charging socket in order to charge the energy storage device.

[0003] The charging unit includes a wire assembly and a charging interface or an interface for connecting the wire assembly to a charging socket and an interface to an energy storage device. The wire assembly or cable extends between the energy storage device and the charging socket. The charging unit is usually a continuous component.

[0004] Motor vehicles can usually be charged with alternating current (AC) or direct current (DC) via an alternating current (AC) cable harness and a direct current (DC) cable harness, respectively.

[0005] According to the prior art, a DC cable harness usually consists of two copper round conductors. When current is transmitted, one of the round conductors is positively charged and the other negatively charged. Copper is suitable for the round conductors because, in addition to the basic requirement of current carrying capacity, it is mechanically flexible and can therefore compensate for tolerances in the arrangement of the charging unit or charging socket and energy storage device.

[0006] But copper has a relatively high heat input under direct current. Copper is relatively cost-intensive and has a high mass.

[0007] WO 2016 / 020512 A1 discloses a vehicle having a storage device for electrical energy that can be recharged by means of a charging cable and an external power source and having a body, the body having at least one body opening that can be closed by a body cover, wherein a charging cable is provided, the charging cable is electrically conductively connected or can be electrically conductively connected to the storage device, and the charging cable extends at least partially inside the body, characterized in that the body opening is a luggage compartment opening or a door opening and the body cover is a luggage compartment lid or a door; the charging cable is constructed as a flexible flat ribbon cable or has at least one flexible flat ribbon cable section; the flexible flat ribbon cable or the at least one flexible flat ribbon cable section can pass through a body gap existing between an edge of the body opening and the body cover, and the flat ribbon cable or the at least one flexible flat ribbon cable section has current-carrying conductors arranged side by side, which are constructed as flat ribbon conductors and are surrounded by a common electrically insulating sheath.

[0008] Typically, a wire assembly according to the prior art includes one or more intermediate pieces for electrically connecting a DC wire and / or an AC wire to a charging socket and an energy storage device. Each intermediate piece causes contact resistance and may cause contact difficulty and / or corrosion. Summary of the invention

[0009] In the context of the prior art, the task of the present disclosure is to propose an improved wire assembly suitable for enriching the prior art. A specific design solution of the present disclosure can solve the task of providing a cost-effective, light-weight and easy-to-maintain wire assembly that avoids intermediate elements for electrical contact.

[0010] This object is achieved by the features of the independent claim. The dependent claims contain preferred developments of the disclosure as content.

[0011] The object is therefore achieved by a cable assembly for conducting electric current from a charging socket of a motor vehicle to an energy storage device of the motor vehicle. The cable assembly comprises a DC cable having two DC wires for conducting direct current from the DC connection of the charging socket to the energy storage device, and an AC cable having a plurality of AC wires for conducting alternating current from the AC connection of the charging socket to the energy storage device. Each DC wire has an aluminum profile as an electrical conductor for conducting direct current.

[0012] The power cord assembly is therefore arranged in the motor vehicle between the charging socket and the energy storage device. The power cord assembly includes the DC power cord and the AC power cord to achieve combined charging. Therefore, both the DC charging process and the AC charging process can be achieved to charge the energy storage device.

[0013] The DC power line has two DC wires, wherein one of the DC wires is assigned to the positive pole and the other DC wire is assigned to the negative pole.

[0014] The AC power line has multiple AC single wires. Therefore, charging can be performed with multi-phase AC and / or three-phase current.

[0015] The DC line and the AC line are each provided for connection to the energy storage device via a corresponding interface. In order to charge the battery cells of the energy storage device, the energy storage device can have power electronics for converting direct current and / or alternating current.

[0016] The cord assembly has an AC plug connection device that can be connected to an AC cord, wherein the AC plug connection device is configured to electrically connect the cord assembly to an AC interface and / or to an energy storage device. Since the AC cord and the charging socket are not fixedly connected to each other, the AC cord can be efficiently installed and / or removed. This allows some components to be replaced, which enables more efficient variant management, such as to be able to take into account vehicle-specific AC cord length differences. This reduces the complexity and cost of the cord assembly and simplifies the installation and maintenance of the cord assembly. The AC plug connection device can avoid other intermediaries between the AC cord and the charging socket and / or the energy storage device, because the AC plug connection device can be directly connected to the charging socket and / or the energy storage device.

[0017] Each DC single line can have an aluminum profile as an electrical conductor for guiding direct current. Therefore, the aluminum profile is provided for guiding direct current. Aluminum is lighter than copper and can be obtained cost-effectively through effective recyclability. In addition, aluminum has a relatively high thermal conductivity. The shape of the DC single line as a profile can improve the heat radiation and / or heat conduction of the heated DC wire and thus achieve effective cooling of the DC wire. Therefore, the charging time for charging the energy storage device can be reduced. The profile is, for example, a component deformed by a flat piece. The DC wire can be provided for conductively fixing to the DC interface and / or the energy storage device through a bolt connection device having a plurality of bolts. Thus, the bolt is used as a fixing device between the DC wire and the charging socket and / or the energy storage device and at the same time as a transmission element for the current. The bolt connection device can avoid the need to set an intermediate piece on the DC interface. No welding is required for connection. Therefore, the wire assembly is easier to install and more cost-effective.

[0018] Each bolt can be arranged perpendicularly to one of the aluminum profiles in the installed state to achieve an effective and reliable bolt connection.

[0019] Each bolt can be in conductive contact with exactly one of the aluminum profiles. As a result, the bolts can be clearly assigned to each pole or DC single conductor.

[0020] Each aluminum profile may have a first through hole and a second through hole, each of which is used to allow one of the bolts to pass through. Therefore, the aluminum profile can be effectively arranged together with the bolt.

[0021] The through holes of each aluminum profile can have different diameters. Therefore, a bolt can be screwed into one of the aluminum profiles while avoiding contact between the bolt and another of the aluminum profiles.

[0022] The above can be summarized as follows in other words and with reference to a specific design solution that does not limit the content of the present disclosure: According to the prior art, an original equipment manufacturer (OEM) charging unit is installed, which is not a continuous component. Here, a round cable is fixed to the charging socket and the high-voltage storage device by means of current-conducting bolts. But in principle, the fewer separation points there are between the individual components, the better. It is therefore proposed that the bolt passes through the flat profile vertically in such a way that the bolt is only connected to one flat profile respectively. The two bolts are in contact with different flat profiles respectively. The two bolts pass through two flat profiles, but only contact one flat profile respectively. The connection of the bolt to the flat profile for electrical connection or electrical separation is achieved by a small or large distance between the bolt and the flat profile.

[0023] In addition, a motor vehicle is provided, which comprises a charging socket, an energy storage device and the above-mentioned wire assembly.

[0024] The motor vehicle may be a passenger car, in particular a car. The motor vehicle may be an electrically driven motor vehicle. For this purpose, the motor vehicle may have an electric drive device, which can be loaded with electric energy from an energy storage device in order to convert the electric energy into kinetic energy. The optionally automated motor vehicle may be designed to at least partially and / or at least temporarily assume longitudinal control and / or lateral control during automatic driving of the motor vehicle. Automatic driving may be performed in such a way that the advancement of the motor vehicle is (largely) autonomous. Automatic driving may be controlled at least partially and / or temporarily by a data processing device. The motor vehicle may be a motor vehicle of an autonomy level of 0 to 5.

[0025] The above description regarding the cordset also applies analogously to the motor vehicle, and vice versa. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Refer to the following Figures 1 to 4 The accompanying drawings are as follows:

[0027] Figure 1 A motor vehicle according to an embodiment of the present disclosure is schematically shown;

[0028] Figure 2 A perspective view showing a power cord assembly according to one aspect of the present disclosure;

[0029] Figure 3 schematically illustrate cross sections of DC wires of a wire assembly according to one aspect of the present disclosure; and

[0030] Figure 4 A bolt connection device of a wire assembly according to one aspect of the present disclosure is schematically shown. DETAILED DESCRIPTION

[0031] Figure 1 A motor vehicle 100 according to one embodiment of the present disclosure is schematically shown.

[0032] The motor vehicle 100 comprises a charging socket 160, an energy storage device 150 and a cable assembly 10. The charging socket 160 is provided for establishing an electrical connection between the motor vehicle 100 and a charging station 200 outside the vehicle. Furthermore, the motor vehicle 100 or its energy storage device 150 can be charged with current and charged.

[0033] For this purpose, the charging socket 160 and the energy storage device 150 are connected via the cable assembly 10 for conducting the current. The cable assembly 10 is provided for conducting the current from the charging socket 160 to the energy storage device 150 .

[0034] The power cord assembly 10 includes a DC power cord 20 and an AC power cord 30 .

[0035] The DC line 20 is provided for conducting the DC power DC from the DC interface 120 of the charging socket 160 to the energy storage device 150 . The AC line 30 is provided for conducting the AC power AC from the AC interface 130 of the charging socket 160 to the energy storage device 150 .

[0036] The AC power line 30 has a plurality of AC single wires 31 (for clarity, only one AC single wire 31 is shown).

[0037] The cable assembly 10 also refers to Figures 2 to 4 to describe.

[0038] Figure 2 A perspective view of a wire assembly 10 according to one aspect of the present disclosure is shown. The wire assembly 10 is a wire assembly 10 for a motor vehicle 10. Such a motor vehicle 10 is referred to as Figure 1 Described. Figure 1 and its description to describe Figure 2 .

[0039] according to Figure 2The AC power line 30 includes a plurality of AC single wires 31 which are arranged in a sheath 38 and are electrically insulated from each other. The AC single wires 31 are made of copper, for example, and each has a circular cross section. The sheath 38 is electrically insulating and is made of plastic, for example.

[0040] The power cord assembly 10 has an AC plug connection device 33 that can be connected to the AC power cord 30. The AC plug connection device 33 is configured to connect the power cord assembly 10 to the AC interface 160. The AC plug connection device 33 has a plug and a socket (not shown) that matches it. At the end of the AC power cord 30 that is not shown, the power cord assembly 10 has another AC plug connection device 33, which is configured to connect the power cord assembly 10 to the energy storage device 150. Therefore, the energy storage device 150 can be electrically connected to the charging socket 160 through the AC plug connection device 33 and the AC power cord 30 for transmitting alternating current AC.

[0041] As in Figure 2 As shown in FIG. 1 , the DC line 20 is provided for being electrically conductively fixed to the DC interface 120 via a screw connection 24 having a plurality of screws 23. Such a screw connection 24 is referred to as Figure 4 In the DC line 20 Figure 2 At the end not shown in the figure, the DC line 20 is provided for being electrically conductively fixed to the energy storage device 150 via another bolt connection device 24 having a plurality of bolts 23. Therefore, the energy storage device 150 can be electrically connected to the charging socket 160 via the bolt connection device 24 and the DC line 20 for transmitting direct current DC. Figure 3 Described in more detail.

[0042] As in Figure 2 As shown in FIG. 1 , the power cord assembly 10 has a ground wire 40 for connecting to a motor vehicle 100 .

[0043] Figure 3 The cross sections of the DC electric wires 20 of the electric wire assembly 10 according to one aspect of the present disclosure are schematically shown respectively. Figure 3 Show reference Figure 1 and 2 The described wire assembly 10. Figure 1 and 2 and its description to describe Figure 3 .

[0044] Figure 3 Four different embodiments of the DC line 20 are shown ( Figure 3 (A), 3(B), 3(C) and 3(D)).

[0045] according to Figure 3The DC power line 20 has two DC single wires 21 and 22 for guiding direct current DC. Each DC single wire 21 and 22 has an aluminum profile 25 as an electrical conductor for guiding direct current DC. The aluminum profile 25 is a flat profile 26. That is, each aluminum profile 25 has two main extension directions, which are horizontal and enter the plane of the figure, and another extension direction, which is a vertical extension direction. The extension dimension of the aluminum profile 25 in the main extension direction is greater than the extension dimension in the other extension direction. The aluminum profile 25 can be manufactured, for example, by rolling and deformation forming.

[0046] The aluminum profiles 25 of the DC single conductors 21 and 22 are arranged parallel to each other. The respective main extension directions of the aluminum profiles 25 define such planes in which the aluminum profiles 25 each have a surface of maximum extension. The aluminum profiles 25 of the DC single conductors 21 and 22 are arranged so that their maximum surfaces are parallel to each other.

[0047] The DC line 20 has an insulation 28. The insulation 28 is provided around the DC wires 21, 22 and between the DC wires 21, 22. The insulation 28 is electrically insulating and is made of plastic, for example.

[0048] Just with Figure 3 (A) to describe the difference Figure 3 (B). According to Figure 3 (B), the DC electric wire 20 has an insulating portion 28. The insulating portion 28 is provided around the DC single wires 21 and 22, respectively. An air gap is provided between the insulating portions 28 of the DC single wires 21 and 22. The air gap can improve heat dissipation from the DC single wires 21 and 22 to the environment.

[0049] Just with Figure 3 (A) to describe the difference Figure 3 (C). According to Figure 3 (C) The DC electric wire 20 has a heat storage paste 27 provided between the DC single wires 21 and 22 .

[0050] Compared to aluminum, the heat storage paste 27 has a high heat capacity and is provided to absorb the heat generated during the charging process in the DC line 20. As a result, the temperature of the DC line 20 does not rise too much, which can facilitate charging.

[0051] The heat storage paste 27 has a paste-like consistency. Therefore, the heat storage paste 27 can be effectively arranged on the correspondingly possibly curved contour of the DC line 20 (see Figure 2 )superior.

[0052] The heat storage paste 27 contacts the DC wires 21, 22 on one of their largest surfaces, so that heat can be effectively transferred from the respective DC wires 21, 22 to the heat storage paste 27. The heat storage paste 27 is electrically insulating and thus forms an electrical insulation between the DC wires 21, 22.

[0053] Just with Figure 3 (C) to describe the difference Figure 3 (D). According to Figure 3 (D), the sheath 28 is used to encapsulate the heat storage paste 27. The heat storage paste 27 is not in direct electrical contact with the DC single wires 21 and 22. Therefore, a conductive heat storage paste 27 can also be used.

[0054] Figure 4 A bolt connection device 24 of a power cord assembly 10 according to one aspect of the present disclosure is schematically illustrated. Figure 4 Show reference Figures 1 to 3 The described wire assembly 10. Figures 1 to 3 and its description to describe Figure 4 .

[0055] The DC line 20 is electrically conductively fixed to the DC connection 120 via a screw connection 24 having two screws 23. In this case, each screw 24 is arranged perpendicular to one of the aluminum profiles 25 in the installed state. In this case, each screw 24 is in electrically conductive contact with exactly one of the aluminum profiles 25.

[0056] Each aluminum profile 25 has a first through hole 29a and a second through hole 29b, each of which is used to allow one of the bolts 24 to pass through. The through holes 29a and 29b of each aluminum profile 25 have different diameters D. In other words, the diameter D of one through hole 29a of each aluminum profile 25 is larger than the diameter D of the other through hole 29b. A tolerance range is provided in each through hole 29b with a smaller diameter D, that is, the diameter D of the corresponding smaller through hole 29b is slightly larger than the diameter of the bolt 24. Here, the diameter D of the corresponding smaller through hole 29b is selected so that a reliable mechanical connection and electrical connection between the DC single wire 21, 22 and the charging socket 160 is achieved. The diameter D of the corresponding larger through hole 29a is selected so that contact between the bolt 24 and the corresponding DC single wire 21, 22 on the larger through hole 29a is excluded. For example, the diameter D of the larger through hole 29a is equal to a multiple of the diameter of the bolt 24.

[0057] The bolt 24 passes through the DC single wires 21 and 22 vertically, so that the bolt 24 is connected to only one DC single wire 21 and 22 respectively. The two bolts 24 are in contact with different DC single wires 21 and 22 respectively. The two bolts 24 pass through the two DC single wires 21 and 22, but are in contact with only one of the DC single wires 21 and 22 respectively. The connection of the bolt 24 and the DC single wire 21 and 22 for electrical connection or electrical separation is achieved by a small or large distance between the bolt 24 and the DC single wire 21 and 22, that is, by different diameters D of the through holes 29a and 29b.

[0058] The cable assembly 10 has a cover 41 or a contact cover. The cover 41 is electrically insulating. The cover 41 can protect the screw connection 24 from mechanical influences.

[0059] Reference numerals list

[0060] 10 Wire Assemblies

[0061] 20 DC wires

[0062] 21 DC single line

[0063] 22 DC single line

[0064] 23 Bolt connection device

[0065] 24 bolts

[0066] 25 Aluminum Profile

[0067] 26 Flat Profiles

[0068] 27 Heat storage paste

[0069] 28 Insulation

[0070] 29a first through hole

[0071] 29b Second through hole

[0072] 30 AC wire

[0073] 31 AC single line

[0074] 33 AC plug connection device

[0075] 38 packs

[0076] 40 ground wire

[0077] 41 Cover

[0078] 100 Motor Vehicles

[0079] 120 DC interface

[0080] 130 AC interface

[0081] 150 Energy storage device

[0082] 160 Charging socket

[0083] 200 charging stations

[0084] AC

[0085] DC direct current

[0086] D diameter

Claims

1. A wire assembly (10) for conducting current from a charging socket (160) of a motor vehicle (100) to an energy storage device (150) of the motor vehicle (100), the wire assembly comprising: - a DC power line (20) having two DC single wires (21, 22) for conducting direct current (DC) from a DC interface (120) of a charging socket (160) to an energy storage device (150); and - an AC power line (30) having a plurality of AC single wires (31) for conducting alternating current (AC) from an AC interface (130) of a charging socket (160) to an energy storage device (150), characterized in that: The cable assembly (10) has an AC plug connection device (33) that can be connected to an AC cable (30), wherein the AC plug connection device (33) is configured to electrically connect the cable assembly (10) to an AC interface (160) and / or to an energy storage device (150).

2. The wire assembly (10) according to claim 1, wherein: Each of the DC single wires (21, 22) has an aluminum profile (25) as an electrical conductor for conducting direct current (DC), and the DC line (20) is provided for being fastened to a DC connection (120) and / or an energy storage device (150) in an electrically conductive manner via a screw connection (24) having a plurality of screws (23).

3. The wire assembly (10) according to claim 1 or 2, wherein: Each of the bolts (24) is arranged perpendicular to one of the aluminum profiles (25) in the installed state.

4. The electric wire assembly according to claim 2 or 3, wherein: Each of the bolts (24) is in electrically conductive contact with exactly one of the aluminum profiles (25).

5. The electric wire assembly according to any one of claims 2 to 4, wherein: Each of the aluminum profiles (25) has a first through hole (29a) and a second through hole (29b), and each of the through holes is used for allowing one of the bolts (24) to pass through.

6. The wire assembly according to claim 5, wherein: The through holes (29a, 29b) of each of the aluminum profiles (25) have different diameters (D).

7. A motor vehicle (100), comprising a charging socket (160), an energy storage device (150) and a cordset (10) according to any one of the preceding claims.

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