Busbar contact device for high voltage applications in vehicles

Abstract

The invention relates to a busbar contact device for high-voltage applications in vehicles, comprising electrical contact elements, a busbar for each electrical contact element, each busbar being formed as a partially flexible busbar such that a first end region and a second end region thereof are rigidly formed, and an intermediate region defining the length thereof is flexibly formed. Furthermore, the busbar contact device has a carrier which is designed to receive at least a part of the electrical contact element and the busbar in the interior thereof, a first part of the carrier being formed as a base and a second part of the carrier being formed as a cover, the cover having an opening in a region, the opening is formed such that the electrical contact element is guided through the opening during installation so as to protrude from the opening after installation, and the cover has dimensions in the area that allow the electrical contact element to move within a predetermined tolerance range.

Description

Technical Field

[0001] The present invention relates to the field of electric vehicles, in particular electrical contact between an inverter and an electric motor. Background Art

[0002] Until now, the electrical contact between the inverter (DC / AC converter) and the electric motor has been achieved via a screw connection. This requires appropriate access to the electrical contact elements. Due to the relatively large number of components required, installation is complex and expensive. Furthermore, a correspondingly large amount of structural space is required, which is becoming increasingly scarce due to the focus on miniaturization. An alternative to screw connections for the electrical contact elements is to use plug-in connections, in which pins are provided on one side and the associated sockets on the other. The problem is that, due to the manufacturing process and the need for blind insertion during installation, tolerances must be set to ensure that the pins securely reach the sockets. Summary of the Invention

[0003] The object of the present invention is to provide a corresponding busbar contact arrangement for high-voltage applications in vehicles, which allows blind connection of electrical contact elements with tolerance compensation.

[0004] This object is achieved by the features of the independent claim. Advantageous embodiments are the subject matter of the dependent claims.

[0005] A busbar contact arrangement for high-voltage applications in vehicles is provided, comprising a plurality of electrical contact elements and a busbar for each electrical contact element. Each busbar is designed as a partially flexible busbar, with its first and second end regions being rigid and its intermediate region, which defines its length, being flexible. Each electrical contact element is fastened by its first end to the first end region of the associated busbar. The busbar contact arrangement also comprises a two-part carrier designed to accommodate at least a portion of the electrical contact elements and the busbar within its interior. The first part of the carrier forms a base, and the second part of the carrier forms a cover. The cover has an opening in its region accommodating the electrical contact elements, the opening being configured such that the electrical contact elements can be guided through the opening during installation and protrude from the opening after installation. Furthermore, the region of the cover accommodating the electrical contact elements has dimensions that allow movement of the electrical contact elements within a predetermined tolerance range. Furthermore, the cover has a hollow space in each case for accommodating one of the busbars in an area adjacent to the opening, wherein the area of ​​each hollow space accommodating the flexible middle area of ​​the busbar has a predetermined shape and the flexible middle area of ​​the busbar is introduced into this shape.

[0006] In one embodiment, a spring element and a recess for accommodating the spring element are arranged in the region of the base directly below each electrical contact element, wherein the spring element is designed to preload the electrical contact elements.

[0007] In one embodiment, a positioning mechanism is provided, which is formed such that it connects the electrical contact elements to one another and positions them.

[0008] In one embodiment, the positioning mechanism is a two-part carrier member or an injection molded encapsulation.

[0009] In one embodiment, a contact opening is provided in the cover for each busbar, which provides access to the busbar for electrical contacting.

[0010] In one embodiment, a projection is provided in the base in the region in which one of the busbars is arranged, which projection is directed toward the cover and is formed such that it presses the busbar against the cover after the cover and base have been mounted.

[0011] In one embodiment, the electrical contact element is formed as a pin or a socket, and / or the spring element is formed as a leaf spring or a compression spring.

[0012] Furthermore, a housing for high-voltage applications in a vehicle is provided, which has a busbar contact arrangement arranged therein.

[0013] Furthermore, an electric drive is provided, which has an electric motor arranged in a first housing with a first busbar contact device and an inverter arranged in a second housing with a second busbar contact device, which is electrically contacted with the first busbar contact device, wherein one of the busbar contact devices is formed as a busbar contact device as described.

[0014] In one embodiment, the electric drive is formed as an electric axle drive.

[0015] Further features and advantages of the invention are apparent from the following description of exemplary embodiments of the invention with reference to the accompanying drawings, which illustrate details according to the invention, and from the claims. The individual features can be realized individually or in multiples in any combination in variants of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Preferred embodiments of the present invention are explained in detail below with reference to the accompanying drawings.

[0017] Figure 1 Schematic diagram showing the principle of blind installation between an inverter and an electric motor according to an embodiment of the present invention,

[0018] Figures 2 to 5Exploded views of different installation steps according to different embodiments of the present invention are shown respectively,

[0019] Figures 6 to 8 Different views of a completely assembled busbar contact arrangement according to different embodiments of the present invention are shown.

[0020] In the following description of the figures, identical elements or functions are provided with the same reference symbols. DETAILED DESCRIPTION

[0021] As already mentioned at the outset, the object of the present invention is to provide a busbar contact arrangement as a plug connection for high-voltage applications, which allows blind contact during installation by allowing corresponding movement tolerances of the electrical contact elements on one side of the plug connection.

[0022] The contact arrangement is formed as a plug connection, ie on one side, for example on the inverter side (on the Figure 1 On one side (the upper housing 1.1 in the figure), the electrical contact elements 10 are formed as pins, while on the other side, for example, on one side of the electric motor (on the attached Figure 1 On the lower housing 1.2), the electrical contact element is formed as a counterpart, ie a socket. Figure 1 In the embodiment shown, the installation direction is indicated by an arrow. It can be seen that the upper housing 1.1 is applied (plugged) onto the lower housing 1.2.

[0023] The proposed busbar contact arrangement can be used for both types of electrical contact elements 10 (plugs or sockets) regardless of the mounting direction.

[0024] In an embodiment, the present invention is used to establish an electrical contact between an inverter and an electric motor. Here, the corresponding housings 1.1, 1.2 of the components (inverter and electric motor) are mechanically connected to each other. In addition, an electrical connection, more precisely a high-voltage connection (in the form of a plug connection) is also established here. In addition, three phases are usually provided in this text, so that on each contact side there are always three busbars 11 (also called busbars) and three pairs of electrical contact elements 10 (for example, three pins and three sockets as counterparts), wherein each electrical contact element is connected with one of its ends to a first end region 110 of the busbar 11 to which it belongs. The other end region 111 of the busbar 11 serves as a contact region for power electronics, such as an AC busbar of an inverter or an AC busbar of an intermediate circuit of an electric motor. The end of the electrical contact element 10 that is not connected to the busbar 11 is used to establish a connection with a counterpart (in the form of a plug connection). Figure 1 The middle is the electrical contact of the socket of the lower housing 1.2).

[0025] Until now, such busbars 11 have been rigid over their entire length. However, according to the present invention, it is now proposed that the intermediate region 112 between the end regions 110 , 111 of the busbar 11 be designed as a flexible region. Flexible busbars 11 are already known in principle, so the exact embodiment for achieving flexibility will not be described in detail. It is mentioned only as an example that a braid of fine wires or a film can serve as the flexible region. The flexible region enables the electrical contact element 10 to be moved relative to the rigid regions 110 , 111, thereby compensating for tolerances during installation and enabling secure insertion into the counterpart.

[0026] The electrical contact elements 10 are usually arranged on the busbar 11 so that the electrical contact elements 10 are arranged side by side, that is, arranged in a row, as shown in the drawings. In the embodiment, a non-conductive positioning mechanism 2 is additionally provided, which can be formed as follows Figures 2 to 8 The positioning means 2 serve, on the one hand, to keep the electrical contact elements 10 at a predetermined distance from one another and, on the other hand, to maintain predetermined air and creepage distances even when the electrical contact elements 10 are relatively close to one another.

[0027] The busbar 11 and the electrical contact element 10 fastened to one end region 110 thereof are arranged in a carrier 3 made of a non-conductive material. Depending on which housing 1.1 or 1.2 the flexibility of the electrical contact is to be provided, the carrier 3 is fastened to the housing 1.1 or 1.2 of the inverter or electric motor, for example, by means of a screw connection (screw 5).

[0028] The carrier 3 is formed in two parts, wherein the first part serves as the base 30 and the second part serves as the cover 31. The two parts are mechanically connected to each other to form a carrier 3, wherein the busbar 11 and a part of the contact element 10 are accommodated in the interior of the carrier 3, as shown in FIG. Figures 6 to 8 shown.

[0029] The cover 31 essentially has two areas. The (first) area of ​​the cover 31 is used to accommodate the busbars 11. To this end, the cover is formed as a hollow space for each busbar 11, which represents a cable channel 310, such as Figure 4 and Figure 5As shown. The cover is thus formed in a pot-like manner in order to accommodate the busbar 11. The exact shape of the cable channel 310 and thus of the carrier 3 depends on the available structural space in the housing 1.1 or 1.2, to which the carrier 3 is fastened. In this case, the shape can also have a curvature in the region of the flexible region 112 of the busbar 11, since the flexible region 112 of the busbar 11 can be introduced into a corresponding shape by folding the flexible region. The carrier 3 can thus be adapted to the shape of the available structural space. The busbar 11 has a predetermined length, wherein the lengths of the rigid regions 110, 111 and the flexible region 112 are selected depending on the available structural space and the shape of the carrier 3.

[0030] Furthermore, in the cover 31, a contact opening 311 is provided in the region of each busbar 11. This contact opening 311 is advantageously spaced apart from the electrical contact elements 10, which are positioned, for example, at the outer ends of the carrier 3, as shown. Figure 6 The contact openings serve to connect the busbars 11 to power electronics of the components fastened to the carrier 3 .

[0031] The second region 312 of the cover is used to accommodate the electrical contact element 10. For this purpose, an opening, for example in the form of an elongated hole, is provided in the cover, which is applied above the electrical contact element 10 when the carrier 3 is mounted, so that the electrical contact element 10 passes through the opening after mounting. Figures 6 to 8 Thus, the electrical contact element 10 , which is embodied as a pin in the embodiment shown by way of example, can be connected to a corresponding counterpart, ie plugged into a socket.

[0032] Due to the basin-like shape of the cover 31, a corresponding space can be provided in the (second) region 312 of the cover 31 where the electrical contact element 10 is located, allowing the electrical contact element 10 to move to a certain extent therein. This allows for adherence to the predetermined tolerances within which the electrical contact element 10 must be movable for blind mating. To this end, the opening is also dimensioned accordingly to allow movement of the electrical contact element in the X and Y directions. This means that the second region 312 is dimensioned slightly larger than the space occupied by the detent mechanism (if present) or the contact element 10, allowing for floating movement within the second region 12.

[0033] The base 30 of the carrier 3 is essentially flat. Only in the area where the busbar 11 is to be secured does the base have projections 300 pointing toward the interior of the carrier 3. After the two parts of the carrier 3 are connected, the projections 300 press the busbar 11 against the cover 31. This presses the busbar 11 against the contact opening 311, facilitating contact. Furthermore, the base 30 has a recess 301 in the area of ​​the electrical contact element 10, pointing toward its underside (away from the cover). In the embodiment, a spring element 4 is arranged in this recess 301. This spring element is compressed (in the Z direction) during the establishment of the plug connection and after the two housings 1.1, 1.2 to be connected are fastened to each other. This preloads the spring element 4 in the installed state and presses the electrical contact element 10 against its counterpart in the other housing 1.1, 1.2. The spring element 4 may be, for example, a compression spring or a leaf spring.

[0034] The figures show two different embodiments of a busbar contact arrangement. Figure 2 、 Figure 4 and Figure 6 An embodiment of a busbar having flexurally rigid end regions 110 , 111 is shown. Figure 3 、 Figure 5 、 Figure 7 and Figure 8 An embodiment of the busbar is shown with straight, rigid end regions 110, 111. The shape of the rigid end regions 110, 111 depends on the shape of the carrier 3. This in turn depends on the available installation space in the housing 1.1, 1.2 in which the carrier is arranged.

[0035] Furthermore, different spring elements 4 are shown in different embodiments. It is evident that Figure 2 、 Figure 4 and Figure 6 The spring element 4 shown can also be used Figure 3 、 Figure 5 、 Figure 7 and Figure 8 The recess 301 for receiving the spring element 4 is formed according to the shape and type of the spring element 4 .

[0036] As shown in the drawings, screws 5 can be provided as connecting elements, which are guided into the housing 1.1, 1.2 (on which the carrier 3 should be mounted) through corresponding screw holes in the already mounted carrier 3 until they reach corresponding receiving portions in the housing 1.1 or 1.2, thereby fastening the carrier 3 to the housing 1.1 or 1.2.

[0037] The busbar contact arrangement described enables blind connection of electrical contact elements with tolerance compensation. To this end, as described, at least one side of the contact element (pin side or socket side) has a defined mobility (displacement and tilting) in the mount. This is achieved, firstly, by a flexible region within the respective busbar and, secondly, by clamping the contact mating element or the contact mating element assembly in the axial direction (Z direction) by means of spring force into the (small) free space (created between the cover 31 and the base 30 via the recess 301), thereby forming a floating contact assembly.

[0038] As already mentioned, the busbar contact arrangement described is used for high-voltage applications in vehicles, specifically in the field of electric drives. In particular, it is used for blind plug connections between electrical contact elements of an inverter and electrical contact elements of an electric motor. The vehicle can be a hybrid vehicle or a purely electric vehicle. The vehicle can be a passenger car, a commercial vehicle, or a passenger vehicle.

[0039] Reference Signs List

[0040] 1.1, 1.2 Upper and lower shells

[0041] 10 Electrical contact element, here a pin or socket

[0042] 11 Bus

[0043] 110 Rigid first end region

[0044] 111 Rigid second end region

[0045] 112 Flexible middle area

[0046] 2 Positioning mechanism

[0047] 3 carriers

[0048] 30 bottom, first part

[0049] 300 bulge

[0050] 301 concavity

[0051] 31 Cover, Part 2

[0052] 310 cable channel, first area 31

[0053] 311 contact opening

[0054] 312 opening, second area of ​​31

[0055] 4 Spring elements

[0056] 5 screws

Claims

1. A busbar contact arrangement for high-voltage applications in a vehicle, comprising: - a plurality of electrical contact elements (10), A busbar (11) for each electrical contact element (10), wherein Each busbar (11) is formed as a partially flexible busbar (11), such that its first and second end regions (110, 111) are rigidly formed and its length-limiting middle region (112) is flexibly formed, and wherein each electrical contact element (10) is fastened with its first end to the first end region (110) of the associated busbar (11), and - a two-part carrier (3) designed to accommodate at least part of the electrical contact element (10) and the busbar (11) in its interior, wherein a first part of the carrier (3) is formed as a base (30) and a second part of the carrier is formed as a cover (31), wherein the cover (31) has an opening (312) in its region for accommodating the electrical contact element (10), the opening being formed such that the electrical contact element (10) is guided through the opening (312) during installation so as to protrude from the opening after installation, and wherein the area of ​​the cover (31) that accommodates the electrical contact element (10) has a size that allows the electrical contact element (10) to move within a preset tolerance range, and The cover (31) has a hollow space (310) in an area adjacent to the opening (312) for accommodating one of the busbars (11), wherein the area of ​​each hollow space (310) that accommodates the flexible middle area (112) of the busbar (11) has a predetermined shape, and the flexible middle area (112) of the busbar (11) is introduced into the shape.

2. The busbar contact device according to claim 1, wherein: In the region of the bottom (30), directly below each electrical contact element (10), a spring element (4) and a recess (301) for accommodating the spring element (4) are provided, wherein the spring element (4) is designed to preload the electrical contact element (10).

3. The busbar contact device according to claim 1 or 2, wherein: A positioning mechanism (2) is provided, which is formed such that it connects the electrical contact elements (10) to each other and positions them.

4. The busbar contact device according to claim 3, wherein: The positioning mechanism (2) is a two-part supporting component or an injection-molded encapsulated component.

5. The busbar contact arrangement according to any one of the preceding claims, wherein: In the cover (31), a contact opening (311) is provided for each busbar (11), which provides access to the busbar (11) for electrical contacting.

6. The busbar contact arrangement according to any one of the preceding claims, wherein: In the bottom (30), a protrusion (300) is provided in each area where one of the busbars (11) is arranged, the protrusion pointing in the direction of the cover (31) and formed so that after the cover (31) and the bottom (30) are mounted, the protrusion presses the busbar (11) toward the cover (31).

7. The busbar contact arrangement according to any one of the preceding claims, wherein: The electrical contact element (10) is formed as a pin or a socket, and / or wherein the spring element (4) is formed as a leaf spring or a compression spring.

8. Housing (1.1, 1.2) for high-voltage applications in vehicles, the housing having a busbar contact arrangement according to any one of the preceding claims arranged therein.

9. An electric drive for a vehicle, comprising an electric motor arranged in a first housing (1.1, 1.2) with a first busbar contact arrangement and an inverter arranged in a second housing (1.1, 1.2) with a second busbar contact arrangement, the second busbar contact arrangement being in electrical contact with the first busbar contact arrangement, wherein: One of the busbar contact devices is formed as a busbar contact device according to any one of claims 1 to 7 . 10 . The electric drive according to claim 9 , which is formed as an electric axle drive.

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