Switching device and energy storage system

Abstract

The present invention relates to a switching device capable of changing the connection state of at least two batteries of a high-voltage energy storage system between a series connection and a parallel connection, and to an energy storage system comprising said switching device. The switching apparatus (100) comprises a fixed busbar arrangement comprising at least a pair of fixed input busbars (140, 142) and a pair of fixed output busbars (144, 146) and a movable busbar arrangement comprising at least one connection busbar (130, 132). The switching apparatus (100) further comprises at least one actuation element (117) configured to change the position of the movable busbar arrangement at least from a first switching position in which each fixed input busbar (140, 140, 140) is switched to a second switching position in which each fixed input busbar (140, 140, 140) is switched to the first switching position, and from the second switching position to the first switching position in which each fixed input busbar (140, 140, 140) is switched to the second switching position in which each fixed input busbar (140, 140, 140). Wherein, in a first switching position, the pair of fixed input busbars (140, 142) are each electrically connected to one of the fixed output busbars (144, 146), and in a second switching position, the pair of fixed input busbars (140, 142) are electrically connected to each other, and wherein the movable busbar arrangement is rotated by at least one actuation element (117) for changing the position of the movable busbar arrangement.

Description

[0001] The present invention relates to a switching device capable of changing the connection state of at least two batteries of a high-voltage energy storage system between a series connection and a parallel connection, and to an energy storage system including the switching device.

[0002] With the advancement of battery-powered vehicles, such as electric vehicles (EVs) and hybrid electric vehicles (HEVs), high-voltage energy storage systems are becoming increasingly common in vehicles. Today, such high-voltage energy storage systems typically provide voltages ranging from 400V to 1kV, or even higher. In these HV systems, the use of contactor devices to connect and disconnect electronic circuits within the energy storage system is well known in the art.

[0003] Conventionally, contactor devices are capable of reversibly changing their state between a closed state (current can flow through the contactor device) and an open state (current is blocked from flowing through the contactor device). Furthermore, it is known to use overcurrent protection devices (such as high-temperature fuses) for irreversibly disconnecting the voltage supply in a high-voltage energy storage system. This is necessary, for example, when a large-scale overcurrent or fault is detected in the electronic circuits of the energy storage system, or in the event of an accident involving a vehicle powered by the power provided by the energy storage system.

[0004] However, depending on the application in which the energy storage system is used, more switching states may be required. In particular, in battery-driven cars, high-voltage driven batteries that provide a voltage in the range of 800V are increasingly used. In order to provide such a high voltage, a plurality of battery modules (or battery packs) are electrically connected to form a high-voltage battery. However, since 400V was generally used as the output voltage of the drive battery before, many chargers or charging stations can only provide a charging voltage of up to 400V, but cannot provide a higher voltage, especially a charging voltage in the range of 800V. In order to solve this problem, it is known to electrically connect two cells (or battery packs) of a high-voltage driven battery (each cell having an output voltage of 400V) in parallel for charging, and to electrically connect the same cells (or battery packs) in series for driving, and then output an output voltage of 800V.

[0005] However, for the above-mentioned single-pole contactor device, at least three contactor devices are required to selectively connect two batteries (or battery strings) in parallel or in series. Therefore, a new switching device is needed that allows a simplified configuration for selectively connecting two batteries (or battery strings) in parallel or in series.

[0006] For example, DE 10 2021 104 142 A1 discloses a switching device having a contact arrangement with a first contact element and a second contact element for selectively bridging the interruption of two switching paths of the switching device. The contact arrangement is moved by an actuator to switch the switching device between a first switching state in which the switching device can connect two batteries in series and a second switching state in which the switching device can connect two batteries in parallel.

[0007] However, the inventors of the present invention have found that since the known switching devices have a relatively complex contact configuration, resulting in a relatively high weight, there is still room for improvement in such switching devices.

[0008] Therefore, the object of the present invention is to provide a switching device which allows changing the connection state of a high-voltage battery by using a simplified contact configuration. Furthermore, the object of the present invention is to provide a space- and weight-saving and economical solution.

[0009] This object is solved by the subject matter of the independent claims. Advantageous aspects of the disclosure are the subject matter of the dependent claims.

[0010] Specifically, according to a first aspect of the present disclosure, a switching device is provided, comprising: a fixed busbar device, the fixed busbar device comprising at least a pair of fixed input busbars and a pair of fixed output busbars; and a movable busbar device, the movable busbar device comprising at least one connecting busbar. The switching device further comprises at least one actuating element, the actuating element being configured to change the position of the movable busbar device at least from a first switching position to a second switching position and from the second switching position to the first switching position, wherein in the first switching position, each fixed input busbar is electrically connected to one of the fixed output busbars, and in the second switching position, the pair of fixed input busbars are electrically connected to each other, and wherein the movable busbar device is rotated by the at least one actuating element to change the position of the movable busbar device.

[0011] By introducing a rotational movement of the movable busbar arrangement, the present disclosure provides a switching device for switching between two output voltage levels with a more efficient contact configuration. Compared to conventional solutions, this allows for a significant reduction in the weight and required space consumed by the switching device. Furthermore, due to the reduction in contact points, it allows for lower contact resistance in the switching path of the switching device, higher mechanical safety due to the inherent avoidance of short circuits, and a reduced risk of buckling. Therefore, rotation of the movable busbar arrangement should specifically mean rotation about the axis of rotation, which does not change the alignment of the connected busbars of the movable busbar arrangement relative to each other, but only changes the orientation of the movable busbar arrangement as a whole.

[0012] According to a second aspect provided on the basis of the first aspect, the switching device also includes a transmission unit, which has at least one driven member and at least one output member, and the at least one driven member and the at least one output member are coupled to each other in a rotationally driven manner within a first angular range, wherein the movable busbar device is supported on the at least one output member, and wherein the driven member is rotated by the at least one actuating element to change the position of the movable busbar device.

[0013] By implementing a transmission unit for transmitting the force generated by the at least one actuating element to the movable busbar arrangement, the switching device allows an efficient force transmission for driving the rotational movement of the movable busbar arrangement between the switching positions.

[0014] According to a third aspect provided on the basis of the second aspect, the rotational movement of the at least one output member is limited to a first angular range. In this way, the third aspect allows for precise positioning of the movable busbar device in the first switching position and the second switching position.

[0015] According to a fourth aspect, provided on the basis of the second or third aspect, when the at least one driven member is driven outside the first angular range, the at least one driven member applies an axial force to the at least one output member, causing the at least one output member to move the movable busbar device in a direction at least substantially parallel to the rotational axis of the driven member. In this way, the fourth aspect allows the torque transmitted to the at least one driven member to be converted into an axial force, so that the torque can be used to move the movable busbar device in a linear motion in a direction parallel to the rotational axis of the driven member with efficient force transmission. This allows the friction applied to the contact points of the fixed busbar and the movable connecting busbar to be reduced. As an alternative, a first dedicated actuator can be provided for generating torque to rotationally move the movable busbar device, and a second dedicated actuator can be provided for linearly moving the movable busbar device to contact the fixed busbar device.

[0016] According to a fifth aspect, provided in addition to any one of the second to fourth aspects, the at least one output member includes a toothed hub profile that engages with the interlocking recess profile of the at least one driven member in a form-fitting and rotationally driven manner within a first angular range, and when the at least one driven member is driven outside the first angular range, the at least one driven member disengages from the toothed hub profile. Thus, this fifth aspect improves torque transmission efficiency between the at least one driven member and the at least one output member within the first angular range. Furthermore, torque applied to the at least one output member by the at least one driven member outside the first angular range is prevented, enabling the transmission unit to effectively transmit force generated by the at least one actuating element.

[0017] According to a sixth aspect, provided in addition to the fifth aspect, the hub of the toothed hub profile is formed as a beveled wedge. In this way, the sixth aspect allows friction-reduced decoupling of the at least one output member from the at least one driven member when the at least one driven member is driven outside the first angular range.

[0018] According to a seventh aspect provided in addition to any one of the second to sixth aspects, the at least one driven member is mechanically connected to a shaft structure, and the shaft structure transmits torque generated by the at least one actuating element for changing the position of the movable busbar device to the at least one driven member. Thus, torque can be transmitted from the at least one actuating element to the shaft structure via gears, which can define an optimal gear ratio for driving the shaft structure.

[0019] According to an eighth aspect, provided on the basis of one of the second to seventh aspects, the housing of the switching device includes at least one output member blocking element, the at least one output member blocking element being configured to engage with at least one lug of the at least one output member to limit the rotational movement of the at least one output member to a first angular range. Alternatively or additionally, the housing of the switching device may include at least one driven member blocking element, the at least one driven member blocking element being configured to engage with at least one lug of the at least one driven member to limit the rotational movement of the at least one driven member to a second angular range that is greater than the first angular range. The respective blocking elements ensure that the range of motion of the at least one driven member and the at least one output member is limited, thereby improving the efficiency of force transmission from the at least one actuating element to the movable busbar device. Therefore, integrally forming the blocking element within the housing of the switching device can save structural space within the switching device and simplify the manufacturing process. However, dedicated blocking elements may also be provided, which can be installed within the switching device as separate components separate from the housing.

[0020] According to a ninth aspect provided in addition to the eighth aspect, the at least one output member blocking element includes at least one asymmetrically formed guide groove, the guide groove being designed to restrict movement of the at least one output member to axial movement when the at least one driven member is driven outside a first angular range. Therefore, when closing or opening contact between the movable contact assembly and the fixed busbar of the switching device, the guide groove enables the movable contact assembly to descend or ascend linearly.

[0021] According to a tenth aspect, provided in conjunction with any one of the second to ninth aspects, at least one connecting busbar of the movable busbar device is resiliently supported on the at least one output member by at least one biasing spring element. This has the advantage that, when the at least one movable busbar is pressed against the fixed busbar device by the at least one output member, the contact force between the movable busbar device and the fixed busbar device of the switching device is controlled. Furthermore, the at least one biasing spring element helps to absorb small misalignments or imbalances between the connecting busbars of the movable busbar device.

[0022] According to an eleventh aspect, in addition to the above aspects, the movable busbar assembly includes a first connecting busbar and a second connecting busbar. In a first switching position, the first connecting busbar and the second connecting busbar each electrically connect one of the input busbars to one of the output busbars. In this manner, the movable busbar assembly allows two batteries to be connected in parallel over a low-resistance connection with only two contact points per connection path.

[0023] According to a twelfth aspect, provided in addition to the eleventh aspect, in the second switching position, the first connecting busbar electrically connects the pair of input busbars to each other, and the second busbar is electrically connected to at most one of the fixed input busbars or one of the fixed output busbars, and at least one contact point of the second connecting busbar is electrically isolated from the remaining busbars of the fixed busbar arrangement. In this manner, the first connecting busbar of the movable busbar arrangement allows two batteries to be connected in series over a low-resistance connection having only two contact points, while the second connecting busbar does not provide any electrical connection. By electrically isolating at least one contact point of the second connecting busbar, for example due to sufficient spacing from the remaining busbars of the fixed busbar arrangement, the occurrence of short circuits or arcing in the switching device is prevented.

[0024] According to a thirteenth aspect provided on the basis of the previous aspects, the switching device further includes a first connection terminal and a second connection terminal (104), the first connection terminal being electrically connected to one of the fixed input busbars for electrically connecting to the first battery, and the second connection terminal being electrically connected to the other of the fixed input busbars for electrically connecting to the second battery.

[0025] According to a fourteenth aspect, provided on the basis of the preceding aspects, the at least one actuating element includes an electric motor configured to rotate at least one driven member of the transmission unit to change the position of the movable busbar device. As an alternative or supplement to the fourteenth aspect, the force generated by the at least one actuating element to change the position of the movable busbar device is transmitted by a worm gear. In this way, it is ensured that the switching device only consumes energy when the position of the switching device changes, and the state of the switching device does not change when the motor is not powered. In this way, the switching device allows for bistability, and when the at least one actuating element suddenly loses power (for example, due to a single point failure, another damage event, or a communication error), the state of the switching device does not change, but the contactor device remains in its previous state. In addition, the worm gear ensures that the movable busbar device is locked in the first switching position or the second switching position. In addition, through its gear ratio, the worm gear helps to provide effective force transmission from the at least one actuating element to the at least one driven member.

[0026] According to the fifteenth aspect, an energy storage system is also provided, which includes at least a first battery and a second battery and a switching device according to any one of the preceding aspects, wherein the first battery and the second battery are electrically connected to the switching device in such a manner that the first battery and the second battery can be switched between a series state and a parallel state through the switching device, in which the first battery and the second battery are electrically connected in series through the switching device, and in the parallel state, the first battery and the second battery are electrically connected in parallel through the switching device.

[0027] Throughout this document, the term "terminal" is intended to describe a point at which a conductor from an electrical device, circuit, or component terminates, and wherein this point is provided for electrically connecting an external electrical device, circuit, or component to the conductor. Furthermore, the terms "electrically connected" and "conductively coupled" describe establishing an electrical connection between at least two electrical devices, components, or conductors that allows for the flow of current. Therefore, this electrical connection should not be limited to the direct coupling of terminals of at least two electrical devices, components, or conductors; other electrical devices, components, or conductors may also be coupled therebetween.

[0028] The accompanying drawings are incorporated into and form a part of the specification to illustrate several examples of the present disclosure. These drawings, together with the description, are used to explain the principles of the present disclosure. The drawings are only for the purpose of illustrating how to make and use the preferred and alternative examples of the present disclosure and should not be interpreted as limiting the present disclosure to only the examples illustrated and described. In addition, several aspects of the examples may form solutions according to the present disclosure alone or in different combinations. Therefore, the examples described below may be considered individually or in any combination. As shown in the accompanying drawings, additional features and advantages will become apparent from the following more detailed description of various examples of the present disclosure, in which the same reference numerals refer to the same elements, and wherein:

[0029] Figure 1 shows a schematic circuit diagram of an exemplary high-voltage energy storage system;

[0030] Figure 2 shows a schematic perspective view of an exemplary switching device;

[0031] Figure 3 shows a schematic perspective view of a portion of the internal components of an exemplary switching device;

[0032] Figure 4 another schematic perspective view showing a portion of the internal components of an exemplary switching device;

[0033] Figure 5 shows a schematic top view of an exemplary switching device in a parallel state;

[0034] Figure 6 A schematic bottom view showing an exemplary contact arrangement of an exemplary switching device in a parallel state;

[0035] Figure 7 shows a schematic top view of an exemplary switching device in a series state;

[0036] Figure 8 a schematic bottom view showing an exemplary contact arrangement of an exemplary switching device in a series state;

[0037] Figure 9 shows another schematic top view of an exemplary switching device in a series state;

[0038] Figure 10 shows a schematic perspective view of an exemplary driven member of an exemplary transmission unit;

[0039] Figure 11 A schematic perspective view showing an exemplary output member of an exemplary transmission unit;

[0040] Figure 12shows another schematic top view of an exemplary switching device in a series state;

[0041] Figure 13 shows a schematic perspective view of an exemplary switching device in a series state;

[0042] Figure 14 A schematic perspective view of an exemplary switching device in a first position illustrating a switching process from a series state to a parallel state;

[0043] Figure 15 a schematic perspective view of an exemplary switching device in a second position illustrating a switching process from a series state to a parallel state;

[0044] Figure 16 a schematic perspective view of an exemplary switching device in a third position illustrating a switching process from a series state to a parallel state;

[0045] Figure 17 shows a schematic perspective view of an exemplary switching device in a parallel state;

[0046] Figure 18 A schematic cross-section of an exemplary switching device is shown.

[0047] Reference will now be made to the drawings and first to the Figure 1 , further explaining the present disclosure. Figure 1 A schematic circuit diagram of an exemplary high voltage energy storage system 10 that can benefit from the ideas of the present disclosure is shown. The energy storage system 10 includes two HV batteries 500(1) and 500(2), which form, for example, drive batteries for a battery-driven car, and a switching device 100. Here and below, it will be assumed that each of the batteries 500(1) and 500(2) has an output voltage of 400V, but other output voltages are also conceivable. Each of the batteries 500(1) and 500(2) is typically formed by several battery modules or battery packs, which in turn are formed by a plurality of battery cells connected in series and / or in parallel. Typically, the number of HV batteries 500 provided in the energy storage system 10 is not limited to two, but more batteries can be used.

[0048] The switching device 100 includes input terminals 102 and 104. The input terminal 102 is configured to be electrically connected to the terminal 502 on the high potential side (+) of the battery 500 (2). The input terminal 104 is configured to be electrically connected to the terminal 504 on the low potential side (-) of the battery 500 (1). In addition, the switching device 100 includes output terminals 106 and 108, which are configured to be electrically connected to a high voltage bus 506, which is, for example, electrically connected to the powertrain of a battery-powered car or electrically connected to a charger (or charging station) for charging the high voltage batteries 500 (1) and 500 (2). The output terminal 106 is electrically connected to the high potential side (+) of the HV bus. Since the high potential side (+) of the HV bus is electrically connected to the terminal 508 on the high potential side (+) of the battery 500 (1) via the node 512, the output terminal 106 is also electrically connected to the terminal 508 on the high potential side (+) of the battery 500 (1). The output terminal 108 is electrically connected to the low potential side (-) of the HV bus. Since the low potential side (-) of the HV bus is electrically connected to the terminal 510 on the low potential side (-) of the battery 500 (2) via the node 514, the output terminal 108 is also electrically connected to the terminal 510 on the low potential side (-) of the battery 500 (2).

[0049] The switching device 100 is configured to switch the first battery 500(1) and the second battery 500(2) between a series state in which the first battery 500(1) and the second battery 500(2) are electrically connected in series by the switching device 100, and a parallel state in which the first battery 500(1) and the second battery 500(2) are electrically connected in parallel by the switching device 100. Therefore, in the series state, the voltage difference between the high potential side (+) and the low potential side (-) of the HV bus 506 is substantially equal to the sum of the voltages provided by the first battery 500(1) and the second battery 500(2) (e.g., 400V+400V=800V). On the other hand, in the parallel state, the voltage difference between the high potential side (+) and the low potential side (-) of the HV bus 506 is substantially equal to the individual voltages provided by the first battery 500(1) and the second battery 500(2) (e.g., 400V). Thus, the switching device 100 allows the voltage applied to the HV bus 506 to be changed to change between a first lower voltage level, which can be equal to the charging voltage provided to the batteries 500(1) and 500(2), and a second higher voltage level, which can be equal to the driving voltage used to drive the battery-powered vehicle.

[0050] Figure 2A schematic perspective view of an exemplary switching device 100 is shown. The switching device 100 includes a housing 110 from which input terminals 102 and 104 and output terminals 106 and 108 extend. Exemplarily, the housing includes two parts, a housing base part 112 and a housing cover 114. In an exemplary configuration, the housing 110 can be a sealed housing, which will allow a vacuum or an electronegative gas to be provided in the space enclosed by the housing 110 to prevent sparks or arcs from being generated when switching the switching device 100. In the example shown, the input terminals 102 and 104 and the output terminals 106 and 108 are formed as cutouts, which can be screwed to corresponding external electrical components, such as terminal clamps of one of the batteries 500(1) or 500(2) or a busbar to which it is electrically connected to the switching device 100. Alternatively, the input terminals 102 and 104 and the output terminals 106 and 108 may be formed as welded or soldered joints, for example, which allow the switching device to be welded or soldered to an external electrical component.

[0051] In the example shown, the housing 110 houses an electric motor 117 as an actuating element that generates a transmission force for switching between the states of the switching device 100. In order to connect the electric motor 117 to a controller of the switching device 100, the electric motor 117 can be connected to a motor connection pin 115 that protrudes from the housing 110 of the switching device. In an alternative configuration, the electric motor 117 can be replaced by another actuating element known in the art of high-voltage switching devices, such as an electromagnetic actuator.

[0052] Figure 3 and Figure 4 A schematic perspective view of a portion of the internal components of the switching device 100 is shown. As shown in the figure, the housing 110 of the switching device houses a fixed contact device and a movable busbar device. In the configuration shown, the fixed busbar device includes a first input busbar 140 and a second input busbar 142 as an input busbar pair, and a first output busbar 144 and a second output busbar 146 as an output busbar pair. In the example shown, the input busbars 140 and 142 are electrically connected to one of the input terminals 102 and 104, respectively, by being formed integrally with the corresponding input terminals. In the example shown, the output busbars 144 and 146 are electrically connected to one of the output terminals 106 and 108, respectively, by being formed integrally with the corresponding output terminals. The movable busbar device is movable in order to change the state of the switching device 100, and the movable busbar device in the configuration shown includes a first connecting busbar 130 and a second connecting busbar 132 (see Figure 4As will be explained later, the first connecting busbar 130 and the second connecting busbar 132 are configured to electrically connect corresponding busbars of the fixed busbar device according to an expected connection state of the switching device 100 .

[0053] It should be noted here that, depending on the application scenario (for example, if the switching device 100 is configured to be electrically connected to more than two batteries (or battery strings) 500), the number of fixed busbars and the number of movable connecting busbars may be different from the number shown in the illustrated example.

[0054] In the illustrated example, when changing the position of the movable busbar device, the force generated by the motor 117 is transmitted to the movable busbar device via a transmission unit 116. The transmission unit 116 includes a shaft 118 with a fixedly mounted drive gear 120. This drive gear 120 meshes with a worm 122, forming a worm gear driven by the motor 117. While the provision of a worm gear is not essential for the switching device 100, it does have the advantage of allowing the torque generated by the motor 117 to be transmitted to the shaft 118 with an optimized transmission ratio compared to a direct mechanical coupling between the motor 117 and the shaft 118 without a gear transmission. Furthermore, the provision of a worm gear prevents reversible force transmission through the worm gear, preventing rotation from being transferred from the shaft 118 back to the motor 117 when the motor 117 is not powered. Thus, by implementing force transmission via the worm gear, the switching device 100 exhibits a self-locking function, wherein only the motor 117 needs to be powered when changing the switching position of the switching device 100.

[0055] In order to selectively convert the force generated by the motor 117 into the linear motion of the movable busbar device or the rotational motion of the movable busbar device, the transmission unit 116 includes a driven member 124 and an output member 128 that carries the movable busbar device. Therefore, the specific mechanical interaction between the driven member 124 and the output member 128 (to be described below) makes it possible to advantageously selectively drive the linear motion or the rotational motion of the movable busbar device of the switching device 100.

[0056] The driven member 124 is fixedly mounted on the shaft 118, for example by integrally forming the driven member 124 on the shaft 188, so that the driven member is mechanically coupled to the drive gear 120 via the shaft 118. Thus, when the motor 117 is powered to change the position of the switching device 100, the shaft 118 transfers torque from the drive gear 120 to the driven member 124. In the example shown, the driven member 124 is formed as a disc-shaped member with a protruding arm 126, the function of which will be described later. Alternatively, the driven member 124 may also have a different external shape, or more than one driven member may be mounted on the shaft 118 and interact with the output member 128 (or more than one output member).

[0057] The output member 128 is rotatably mounted on the shaft 118, adjacent to the driven member 124. The shaft thus defines an axis of rotation for the driven member 124 and the output member 128. In the example shown, the output member 128 is formed as a disc-shaped member. Alternatively, the output member 128 may also have a different external shape, or more than one output member may be coupled to the shaft 118 and interact with the driven member 124 (or more than one driven member). The output member 128 is axially fixed to the shaft 118 by a return spring 129, which is preferably threaded onto the shaft 118 and allows the output member 128 to perform linear movement in a direction parallel to the extension direction of the shaft 118 (also referred to as the axial direction), as will be explained later.

[0058] like Figure 4 As shown in the example of FIG, the output member 128 includes two matching half shells, a lower half shell 134 carrying the movable busbar device and an upper half shell 136 mounted on the lower half shell 134 to form the housing of the output member 128. Alternatively, the housing of the output member 128 can also be formed from a single piece, and the connecting busbars can be mounted to the output member 128, for example, during the molding process. For illustrative purposes, the upper half shell 136 of the output member 128 is shown in FIG. Figure 3 130 and 132 are indicated only by dashed lines. Thus, it can be seen that the first connecting busbar 130 and the second connecting busbar 132 are disposed within the busbar accommodation portion 139 of the output member 128. Furthermore, a preloaded spring element 138 is disposed within the interior of the output member 128 to elastically support the connecting busbars 130 and 132 within the output member 128. This allows for better control of the contact force between the connecting busbars 130 and 132 and the fixed busbars of the switching device 100 when the output member 128 exerts a force on the movable busbar assembly to press the movable busbar assembly onto the fixed busbar assembly. Furthermore, the preloaded spring element 138 helps to absorb small misalignments or imbalances between the connecting busbars 130 and 132 of the movable busbar assembly.

[0059] Figure 5 and Figure 6 The switching device 100 is schematically shown in a parallel state. Figure 5 A schematic top view of the switching device 100 without the housing cover 114 is shown in order to illustrate the positions of the individual components of the transmission unit 116 in the parallel state. Figure 6A schematic bottom view of the fixed contact device and the movable contact device is shown to illustrate the position of the movable busbar device in the parallel state. As shown in the figure, in the parallel state, the movable busbar device is in a first switching position, wherein the first input busbar 140 is electrically connected to the first output busbar 144 via the first connecting busbar 130. In addition, in the first switching position, the second input busbar 142 is electrically connected to the second output busbar 146 via the second connecting busbar 132. Therefore, in the parallel state, the switching device 100 electrically connects the two batteries connected to the input terminals 102 and 104 in parallel (for example, in Figure 1 HV energy storage system 10).

[0060] Figure 7 and Figure 8 The switching device 100 is schematically shown in a series state. Figure 7 A schematic top view of the switching device 200 is shown without the housing cover 114 in order to illustrate the position of the individual components of the transmission unit 116 in the series state. Figure 8 A schematic bottom view of the fixed and movable contact arrangements of switching device 100 in the series connection state is shown to illustrate the positions of connecting busbars 130 and 132 in the series connection state. As shown, in the series connection state, the movable busbar arrangement is in the second switching position, in which first input busbar 140 and second input busbar 142 are electrically connected to each other via first connecting busbar 130. Thus, in the series connection state, switching device 100 electrically connects the two batteries connected to input terminals 102 and 104 in series.

[0061] In the series configuration, first connecting busbar 130 is in electrical contact with both input busbars 140 and 142, while second connecting busbar 132 is in electrical contact with at most one of the remaining fixed busbars. In particular, in the exemplary configuration shown, second connecting busbar 132 is in electrical contact with second output busbar 146. The free contact point 148 of second connecting busbar 132 is electrically insulated from the remaining fixed busbars. In particular, in the exemplary configuration shown, second connecting busbar 132 is electrically insulated from input busbars 140 and 142, as well as from first output busbar 144, by a distance that is sufficiently large to prevent any arcing or other short circuits. It should be noted that, because connecting busbars 130 and 132 are mounted on a pivoting output member, the necessary spacing between free contact point 148 of second connecting busbar 132 and the remaining fixed busbars is particularly easy to achieve. Additional insulating elements ensuring insulation between the free contact point 148 of the second connecting busbar 132 and the remaining fixed busbars are not necessary but may additionally be provided to enhance the safety and reliability of the switching device 100 .

[0062] To move the movable busbar assembly between the first and second switching positions, the movable busbar assembly is rotated in a plane parallel to the direction of extension of the connecting busbars 130 and 132 of the movable busbar assembly, with axis 118 serving as the rotation axis. This means that rotation of the movable busbar assembly does not alter the alignment of the connecting busbars 130 and 132 relative to one another, but rather only changes the orientation of the movable busbar assembly as a whole. Consequently, rotation of the movable busbar assembly does not, for example, cause the connecting busbars 130 and 132 to tilt or twist relative to one another.

[0063] To rotate the movable busbar arrangement, the output member 128, on which the first and second connecting busbars 130 and 132 are mounted, is coupled to the driven member 124 in a rotationally driven manner within a first angular range. Thus, the output member 128 rotates about its rotation axis, which corresponds to the rotation axis of the driven member 124 and is defined by the shaft 118.

[0064] like Figure 9 As shown, the freedom of rotational movement of the output member 128 is limited to a first angular range by a protruding lug 158 projecting from the circular base of the output member 128. This protruding lug 158 interacts with a wall structure 156 of the switching device, which serves as an output member blocking element. The wall structure 156 extends upward from the base of the housing 110, particularly from the housing base portion 112, and circumferentially surrounds the output member 128. Therefore, the inner radius of the wall structure 156 is designed to be smaller than the radius of the output member 128 at the location of the protruding lug 158. When the protruding lug 158 reaches the limit of the first angular range, it abuts against the wall structure 156, engaging with the wall structure 156 to prevent rotational movement of the output member 128 in either the clockwise or counterclockwise direction. Figure 9 The boundaries of a first angular range, in which the protruding lug 158 engages the wall structure 156, are schematically indicated by dashed lines 150 and 152. Dashed lines 150 and 152 encompass the first angular range, which serves as a motion region I for the output member 128, or more specifically, a motion region within which the lug 158 permits rotational movement of the output member 128. Arrows 154 schematically indicate possible directions of movement of the output member 128 within the first angular range. To permit rotation of the output member 128, and in particular rotation of the protruding lug 158 within the first angular range, the height of the intermediate portion 157 of the wall structure 156 is lower than the height of the remainder of the wall structure 156 within the first angular range.

[0065] In the example shown, the wall structure 156 is provided as a single part that is integrally formed with the base portion of the housing 110. However, this is merely an example, and the wall structure 156 may also be formed from several separate parts and / or be provided within the switching device 100 separately from the housing 110. Furthermore, in the example shown, two lugs 158 are provided for the output member 128. However, depending on the application scenario, another number of lugs 158 may be provided, and the design of the wall structure 156 (or another output member blocking element) may be adjusted accordingly.

[0066] As described above, in order to be rotated, the output member 128 is coupled to the driven member 124 in a rotationally driven manner at least when the driven member 124 drives the output member 128 to rotate between the boundaries of the first angular range. This allows the driven member 124 to transmit the torque generated by the motor 117 to the output member 128 and rotate the output member 128 within the first angular range. In order to couple the output member 128 to the driven member 124 within the first angular range, the driven member may include a plurality of notches 160 (see FIG. 16 ) on its bottom side. Figure 10 ) (but at least one notch 160) to form a notch profile. The output member 128 may include a plurality of hubs 162 (see FIG. 1 ) on its top side (ie, on the side facing away from the connecting busbars 130 and 132). Figure 11 ) (but at least one hub 162) to form an interlocking hub profile that can mate with the recess profile of the driven member. To achieve optimal torque transmission, when the driven member 124 is engaged, the number of hubs 162 preferably corresponds to the number of recesses 160, and the hubs 162 preferably mate with the recesses 160 in a form-fitting manner. However, other configurations are possible depending on the application scenario.

[0067] While the rotational movement of the movable busbar assembly between the first switching position and the second switching position offers numerous advantages, such as allowing for a reduction in the overall weight of the switching device 100, the purely rotational movement of the movable busbar assembly increases friction on the contact elements mounted at the busbar assembly contact points, potentially damaging the contact elements. However, contact elements made of, for example, silver or any silver alloy to form silver buttons, or other suitable conductive materials, are generally sensitive structures and are advantageous because they allow for reduced contact resistance in both the series and parallel states. Consequently, damage to the contact elements could result in a significant degradation in the performance of the switching device 100.

[0068] Therefore, to reduce friction on the contact elements, when opening the contacts between the movable contact assembly and the fixed contact assembly, the movable busbar assembly is advantageously separated from the fixed busbars of the fixed busbar assembly by a linear motion before the movable contact assembly is rotated. For example, when opening the contacts of the switching device 100, the movable busbar assembly is raised in a direction parallel to the rotation axis of the output member 128 (or the driven member 124) before the movable contact assembly is rotated. Similarly, when closing the contacts between the movable contact assembly and the fixed contact assembly, the movable busbar assembly is advantageously brought into contact with the fixed busbars of the fixed busbar assembly by a linear motion after the rotational movement of the movable contact assembly has been performed. For example, when opening the contacts of the switching device 100, the movable busbar assembly is lowered in a direction parallel to the rotation axis of the output member 128 (or the driven member 124) after the rotational movement of the movable contact assembly has been performed.

[0069] Typically, in order to linearly move the movable busbar device, a second dedicated actuating element may be provided in the switching device 100, wherein the second actuating element generates a force for linearly moving the movable busbar device, for example by lifting and lowering the output element 128. However, in order to simplify the configuration of the switching device 100, the linear movement of the movable busbar device is advantageously also driven by the electric motor 117, and the transmission unit 116 is designed in such a way that, in order to linearly move the movable busbar device, the torque generated by the electric motor 117 is converted into a linear force.

[0070] To this end, when driven member 124 rotates outside a first angular range that limits the rotational movement of output member 128, transmission unit 116 converts the torque applied to driven member 124 into an axial force that acts on output member 128 in a direction parallel to the extension direction of shaft 118. The applied axial force forces output member 128 toward the fixed contact arrangement. Specifically, when driven member 124 is driven outside the first angular range, notch 160 of driven member 124 disengages from hub 162 of output member 128 and begins to slide past hub 162. To ensure smooth disengagement when hub 162 disengages from notch 160, in a preferred configuration, hub 162 of the toothed hub profile is formed as a beveled wedge, with notch 160 having a corresponding mating profile.

[0071] Upon disengagement, output member 128 is displaced by hub 162 in a direction parallel to the direction of extension of shaft 118 due to the interaction between hub 162 and intermediate region 168 of driven member 124, which is disposed between each adjacent notch 160 and extends at a greater height than notches 160. The maximum axial displacement of output member 128 (and thus of connection bars 130 and 132 carried by output member 128) is determined by the maximum height of hub 162 and the height of intermediate region 168 (compared to notches 160). To utilize this maximum displacement to position connection bars 130 and 132 on the fixed contact arrangement and to prevent undesired recoupling of driven member 124 with output member 128 when driven member 124 is driven outside the first angular range, the rotational movement of driven member 124 is limited to a second angular range.

[0072] For this purpose, Figure 12 As shown, the freedom of rotational movement of the driven member 124 is limited to a second angular range, i.e., the first angular range, by a protruding lug 172 that protrudes from the arm 126 of the driven member 124. This protruding lug 172 interacts with a wall structure 170 that serves as a driven member blocking element. This wall structure 170 extends upward from the base of the housing base portion 112 at least to a height at which it can interact with the protruding lug 172. Therefore, the inner radius of the wall structure 170 is designed to be smaller than the radius of the driven member 124 at the location of the protruding lug 172. When the protruding lug 172 reaches the boundary of the second angular range, it abuts against the wall structure 170, engaging with the wall structure 170 and thereby preventing clockwise or counterclockwise rotational movement of the driven member 124. Figure 12 The boundaries of the second angular range are schematically indicated by solid lines 164 and 166, wherein, based on the boundaries of the first angular range indicated by dashed lines 150 and 152, the protruding lugs 172 engage with the wall structure 170 (for illustrative purposes, only one lug 172 is shown). In the example shown, one lug 172 is provided on each arm 126 of the driven member 124. However, depending on the application scenario, there may be a different number of lugs 172 on each arm 126 or a different number of arms 126, and the design of the wall structure 170 may be adjusted accordingly.

[0073] like Figure 12As shown, the radial freedom of movement of the driven member 124, or more specifically, the radial movement of the lug 172 of the driven member 128, is less restricted than the radial freedom of movement of the output member 128, or more specifically, the radial movement of the lug 158 of the output member 128. In particular, the second angular range includes a motion region I in which the driven member 124 is rotatably coupled to the output member 128, and further includes a motion region II (between the solid line 164 and the dashed line 150) and a motion region III (between the solid line 166 and the dashed line 152) in which the driven member 124 exerts an axial force on the output member 128 to change its height. Arrows 154 schematically indicate the possible directions of movement of the driven member 124 within the first angular range.

[0074] Figures 13 to 17 shows that when the switching device 100 is switched from the series state ( Figure 13 ) Switch to parallel state (see Figure 17 ) is a schematic perspective view of the switching device 100 at various points in the switching process. In order to illustrate the internal components of the switching device 100, especially the function of the transmission unit 116 during the switching process, Figures 13 to 17 Only a portion of the housing 110 in the switching device 100 is shown in FIG.

[0075] exist Figure 13 In the illustrated series position, driven member 124 experiences its maximum displacement in the clockwise direction (as viewed from the top of switching device 100), causing lug 172 of driven member 124 to abut against wall structure 170 in the clockwise direction. Similarly, output member 128 experiences its maximum displacement in the clockwise direction, causing lug 158 of output member 128 to abut against wall structure 156 in the clockwise direction. Lug 158 is thus guided by first guide slot 174. When the movable busbar assembly opens or closes contact with the fixed busbar assembly in the second switching position, first guide slot 174, through engagement with lug 158, restricts the movement of output member 128 to axial movement. Because first guide slot 174 is defined on one side by a portion of wall structure 156 extending to its full height and on the other side by a lowered intermediate portion 157 of wall structure 156, the sidewalls of first guide slot 174 have asymmetrical heights.

[0076] In the series connection state, the hub 162 of the output member 128 is disengaged from the recess 160 of the driven member, and due to the interaction between the hub 162 and the intermediate region 168 of the driven member 124, the output member 128 is displaced to the maximum extent in the axial direction (indicated by arrow 176) away from the driven member 124. Accordingly, the output member 128 presses the first connecting busbar 130 and the second connecting busbar 132 against the fixed busbar device, thereby electrically connecting the first input busbar 140 and the second input busbar 142 to each other via the first connecting busbar 130 (see FIG. 1 ). Figure 8 ).

[0077] Figure 14 The switching device is shown in the first position after the driven member 124 is rotated by the motor 117 in a counterclockwise direction (as viewed from the top of the switching device 100) away from the series state. Figure 12 In this position of the position in the movement region II, the displacement of the driven member 124 is reduced, but the driven member 124 is still driven outside the first angular range, so that the output member 128 still experiences its maximum displacement in the clockwise direction. Therefore, compared with the series state, the output member 128 does not rotate, so that the movable busbar device still has the same orientation as in the second switching position, but has been lifted above the fixed busbar device. However, due to the restoring force exerted by the return spring 129 on the output member 128 in the axial direction opposite to the direction of the arrow, the hub 162 of the output member 128 has partially engaged with the recess 160 of the driven member 124. Therefore, Figure 13 Compared to the series state, the connecting busbars 130 and 132 of the movable busbar device are lifted in a linear motion. In this position, the movement of the output member 128 is still limited to linear movement in the axial direction by the middle portion 157 of the wall structure 156, which engages with the lug 158 of the output member 128 until the hub profile of the output member 128 is fully engaged with the recess profile of the driven member 124.

[0078] Figure 15 The switching device 100 is shown in the second position after the driven member 124 is rotated in the counterclockwise direction by the motor 117 away from the series state. Figure 12 In this position of the position in the movement range I of the output member 128, the output member 128 is coupled to the driven member in a form-fitting and rotationally driven manner by the form-fitting engagement of the hub profile with the recess profile (see also Figure 18(a cross-section). Therefore, in this position, the movable busbar assembly is fully elevated and ready for rotation. The torque applied to driven member 124 is transmitted to output member 128, driving output member 128 counterclockwise, causing the movable busbar assembly to rotate counterclockwise toward the first switching position. Because output member 128 is fully elevated, its lug 158 is unobstructed by the intermediate portion 157 of wall structure 156.

[0079] Figure 16 The switching device 100 is shown in the third position after the driven member 124 is rotated in the counterclockwise direction by the motor 117 away from the series state. Figure 12 In this position, which is the boundary of the movement area I shown by the dashed line 152, the output member reaches its maximum displacement in the counterclockwise direction. In this position, the lug 158 of the output member abuts against the wall structure 156 above the second guide groove 178, which limits the movement of the output member 128 to axial movement through the engagement of the lug 158. The movable busbar device has the same orientation as in the first switching position (see Figure 6 ), but still higher than the fixed busbar device. Due to the restriction of the rotational movement of the output member 128, when the driven member 124 rotates further counterclockwise from the third position, that is, enters Figure 12 When the driven member 124 enters the movement region III, the notch 160 begins to disengage from the hub 162. Therefore, when the driven member 124 rotates further counterclockwise from the third position, the driven member 124 applies a rotational force in the axial direction to the output member 128 through the interaction between the hub 162 of the output member 128 and the intermediate region 168 of the driven member 124, thereby causing the output member 128 to move in the axial direction along the direction 176.

[0080] Figure 17 The switching device 100 is shown in a series configuration, with the driven member 124 undergoing its maximum displacement in the counterclockwise direction, causing the lug 172 of the driven member 124 to abut against the wall structure 170 in the counterclockwise position. Similarly, the output member 128 undergoes its maximum displacement in the counterclockwise direction, causing the lug 158 of the output member 128 to abut against the wall structure 156 in the counterclockwise direction. Consequently, the lug 158 is guided by a second guide slot 178, which limits the movement of the output member 128 to axial movement when the movable busbar arrangement opens or closes contact with the fixed busbar arrangement in the first switching position. Because the second guide slot 178 is defined on one side by a portion of the wall structure 156 extending to its full height and on the other side by a lowered intermediate portion 157 of the wall structure 156, the sidewalls of the second guide slot 178 have asymmetrical heights.

[0081] In the series connection state, the hub 162 of the output member 128 is disengaged from the recess 160 of the driven member, and the output member 128 is displaced to its maximum extent in the axial direction (indicated by arrow 176) away from the driven member 124 by the interaction between the hub 162 and the intermediate region 168 of the driven member 124. Therefore, in this position, the output member 128 presses the first connecting busbar 130 and the second connecting busbar 132 against the fixed busbar device, so that the first input busbar 140 is electrically connected to the first output busbar 144 via the first connecting busbar 130, and the second input busbar 142 is electrically connected to the second output busbar 146 via the second connecting busbar 132 (see FIG. 1 ). Figure 6 ).

[0082] The series state of the switching device 100 ( Figure 13 ) and parallel state ( Figure 17 ) is reversible, therefore, when the driven member 124 is driven in the clockwise direction by the motor 117, the switching process from the parallel state to the series state is similar to the above description.

[0083] Reference Numbers

[0084]

[0085]

Claims

1. A switching device (100), comprising: A fixed busbar device, the fixed busbar device comprising at least a pair of fixed input busbars (140, 142) and a pair of fixed output busbars (144, 146); A movable busbar device, the movable busbar device comprising at least one connecting busbar (130, 132); as well as at least one actuating element (117) configured to change the position of the movable busbar device at least from a first switching position to a second switching position and from the second switching position to the first switching position; wherein, in the first switching position, each of the fixed input busbars (140, 142) is electrically connected to one of the fixed output busbars (144, 146), and in the second switching position, the pair of fixed input busbars (140, 142) are electrically connected to each other, and The movable busbar device is rotated by the at least one actuating element (117) to change the position of the movable busbar device.

2. The switching device (100) according to claim 1, further comprising a transmission unit (116), the transmission unit having at least one driven member (124) and at least one output member (128), the at least one driven member and the at least one output member being coupled to each other in a rotationally driven manner within a first angular range, wherein The movable busbar arrangement is supported on the at least one output member (128), and wherein the driven member (124) is rotated by the at least one actuating element (117) to change the position of the movable busbar arrangement.

3. The switching device (100) according to claim 2, wherein: Rotational movement of the at least one output member (128) is limited to the first angular range.

4. The switching device (100) according to any one of claims 2 or 3, wherein: When the at least one driven member (124) is driven outside the first angular range, the at least one driven member (124) exerts an axial force on the at least one output member (128), thereby causing the at least one output member (128) to move the movable busbar device in a direction at least substantially parallel to the rotational axis of the driven member (124).

5. The switching device (100) according to any one of claims 2 to 4, wherein: The at least one output member (128) comprises a toothed hub profile that engages with the interlocking notch profile of the at least one driven member (124) in a form-fitting and rotationally driving manner within the first angular range, and disengages from the toothed hub profile when the at least one driven member (124) is driven outside the first angular range.

6. The switching device (100) according to claim 5, wherein: The hub (160) of the toothed hub profile is formed as a beveled wedge.

7. The switching device (100) according to any one of claims 2 to 6, wherein: The at least one driven member (124) is mechanically connected to a shaft structure (118) that transmits a torque generated by the at least one actuating element (117) for changing the position of the movable busbar device to the at least one driven member (124).

8. The switching device (100) according to any one of claims 2 to 7, wherein: The housing (110) of the switching device (100) includes at least one output member blocking element (156), which is configured to engage with at least one lug (158) of the at least one output member (128) for limiting the rotational movement of the at least one output member (128) within the first angular range, and / or the housing (110) of the switching device (100) includes at least one driven member blocking element (170), which is configured to engage with at least one lug (172) of the at least one driven member (124) for limiting the rotational movement of the at least one driven member (124) within a second angular range that is greater than the first angular range.

9. The switching device (100) according to claim 8, wherein: The at least one output member blocking element (156) includes at least one asymmetrically formed guide slot (174, 178) designed to limit movement of the at least one output member (128) to axial movement when the at least one driven member (124) is driven outside of a first angular range.

10. The switching device (100) according to any one of claims 2 to 9, wherein: At least one connecting busbar (130, 132) of the movable busbar arrangement is elastically supported on the at least one output member by at least one biased spring element (138).

11. A switching device according to any one of the preceding claims, wherein The movable busbar device comprises a first connecting busbar (130) and a second connecting busbar (132), wherein in a first switching position, the first connecting busbar (130) and the second connecting busbar (132) respectively electrically connect one of the fixed input busbars (140, 142) to one of the fixed output busbars (144, 146).

12. The switching device (100) according to claim 11, wherein In the second switching position, the first connecting busbar (130) electrically connects the pair of fixed input busbars (140, 142) to each other, and the second busbar (132) is electrically connected to at most one of the fixed input busbars (140, 142) or one of the fixed output busbars (144, 146), and at least one contact point (148) of the second connecting busbar (132) is electrically insulated from the remaining busbars of the fixed busbar arrangement.

13. The switching device (100) according to any one of the preceding claims, further comprising a first connecting terminal (102) and a second connecting terminal (104), wherein the first connecting terminal (102) is electrically connected to one of the fixed input busbars (140) for electrically connecting to a first battery, and the second connecting terminal (104) is electrically connected to another of the fixed input busbars (142) for electrically connecting to a second battery.

14. The switching device (100) according to any one of the preceding claims, wherein The at least one actuating element (117) comprises an electric motor configured to rotate the at least one driven member (124) of the transmission unit (116) to change the position of the movable busbar arrangement, and / or wherein, The force generated by the at least one actuating element (117) for changing the position of the movable busbar device is transmitted by a worm gear (120, 122).

15. An energy storage system (10), comprising at least a first battery (500(1)) and a second battery (500(2)) and a switching device (100) according to any one of the preceding claims, wherein The first battery (500(1)) and the second battery (500(2)) are electrically connected to the switching device (100) in such a manner that the first battery (500(1)) and the second battery (500(2)) can be switched between a series state and a parallel state through the switching device (100). In the series state, the first battery (500(1)) and the second battery (500(2)) are electrically connected in series through the switching device (100), and in the parallel state, the first battery (500(1)) and the second battery (500(2)) are electrically connected in parallel through the switching device (100).

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