Charger and motor vehicle

Abstract

The invention relates to a charger (6) which is configured as an on-board charger (7) for wired and wireless charging of a traction battery (2) of a motor vehicle (1), comprising a housing (8), power electronics (11), an induction coil (12), a cooling circuit (15) for guiding a coolant and for cooling the power electronics (11) and the induction coil (12), a cable interface (16) for electrically connecting the charger (6) to a charging socket (4) of the motor vehicle (1) which is configured for wired charging, a battery interface (17) for electrically connecting to the traction battery (2), a control interface (18) for electrically connecting to a control device (5) for controlling the charging process, a coolant inlet interface (19) for supplying coolant to the cooling circuit (15), and a coolant outlet interface (20) for conducting coolant out of the cooling circuit (15).

Description

Technical Field

[0001] This invention relates to a charger for battery-electric motor vehicles and a motor vehicle equipped with such a charger. Background Technology

[0002] Battery-electric vehicles have a traction battery that can be charged using an external power source. To charge the traction battery, the vehicle is equipped with a charger that supplies electrical energy from the external power source to the traction battery. Here, the alternating current supplied to the charger is converted to direct current, which can then be supplied to the traction battery for charging.

[0003] To connect electrically to a corresponding external energy source, motor vehicles are typically equipped with a charging socket inside the vehicle that is electrically connected to a charger, allowing for wired charging. For this purpose, a charging cable connected to the external energy source is plugged into the charging socket. Furthermore, inductive charging systems for wirelessly charging traction batteries are known, in which the external energy source is electrically connected to a fixed inductive charging device, which can be, for example, fixedly positioned on the ground in the parking space of the motor vehicle. The inductive charging system also includes a mobile inductive charging device, which is located in an area under the vehicle and electrically connected to the charger. The vehicle can now be positioned in the parking space, allowing electrical energy to be transferred inductively from the fixed inductive charging device to the mobile inductive charging device, and then supplied to the charger. The fixed inductive charging device has an induction coil, which can be referred to as a transmitting coil. The mobile inductive charging device also has an induction coil, which can be referred to as a receiving coil.

[0004] If a vehicle is configured for both wired and wireless charging, separate chargers are typically used for each: one for wired charging and one for wireless charging. These two separate chargers are electrically connected to the traction battery and, respectively, to a controller that manages the charging process. Furthermore, each of these separate chargers may be equipped with a cooling circuit, both of which can be integrated into the vehicle's cooling system. Since these chargers are permanently connected to the vehicle during normal use, they can also be referred to as on-board chargers. Summary of the Invention

[0005] The present invention addresses the following problem: to provide an improved or at least another embodiment of the aforementioned type of charger and motor vehicle equipped with such charger, which is particularly noteworthy in that it requires less installation space and can be implemented relatively economically.

[0006] This problem is solved according to the invention by the subject matter of the independent claims. Advantageous embodiments are the subject matter of the dependent claims.

[0007] This invention is based on the general concept of combining a charger configured for wired charging and a charger configured for wireless charging, such that a common housing can be used for this purpose, wherein components for the same purpose in the two different chargers are integrated together in the combined charger. By integrating the two chargers into a common housing, the combined charger according to the invention requires less installation space than two separate chargers. By sharing the components of the combined charger, fewer components are required compared to two separate chargers, thereby reducing manufacturing costs.

[0008] In other words, the present invention proposes a charger for battery-electric motor vehicles, which is configured as an on-board charger for wired and wireless charging of the traction battery of the motor vehicle. Therefore, the charger has: a housing; power electronics disposed inside the housing; an induction coil mounted on or in the housing and electrically connected to the power electronics; a cooling circuit disposed on or in the housing for guiding coolant and for cooling the power electronics and the induction coil; a cable interface disposed on the outside of the housing and electrically connected to the power electronics for electrically connecting the charger to a charging socket of a motor vehicle configured for wired charging; a battery interface disposed on the outside of the housing and electrically connected to the power electronics for electrically connecting to a traction battery; a control interface disposed on the outside of the housing and electrically connected to the power electronics for electrically connecting to a controller for controlling the charging process; a coolant inlet interface disposed on the outside of the housing and fluidly connected to the cooling circuit for supplying coolant to the cooling circuit; and a coolant outlet interface disposed on the outside of the housing and fluidly connected to the cooling circuit for discharging coolant from the cooling circuit.

[0009] Therefore, the charger proposed herein has a battery interface that can be used to supply power to the traction battery during both wired and wireless charging. Furthermore, the charger proposed herein has a control interface that can be used to control the charging process during both wired and wireless charging. Additionally, a common cooling circuit is provided that can be used to cool the power electronics and, if necessary, the induction coil during both wired and wireless charging.

[0010] In this context, “configuration” is equivalent to “configuration” and / or “setup” and / or “programming”, so the expression “configuration such that” is equivalent to the expression “configuration and / or setup and / or programming such that”.

[0011] The cable interface can be designed for high voltage and high power, and can be configured as a three-phase interface for this purpose.

[0012] The induction coil can be placed inside the housing or on the outside of the housing.

[0013] According to an advantageous embodiment, the charger may have an on-board electrical grid interface disposed on the outside of the housing, electrically connected to power electronics, for connecting to the vehicle's on-board electrical grid. Through this interface, electrical energy can be supplied to the vehicle's on-board electrical grid; for example, during charging, electrical energy can be supplied to electrical components of the vehicle connected to the on-board electrical grid, such as the controller. Similarly, conventional on-board batteries can be charged during the charging process in this manner.

[0014] In another embodiment, the charger may have a cooling plate disposed on or within the housing, in which a cooling circuit is constructed. This cooling plate can be arranged flat and planar, requiring less installation space and capable of dissipating a large amount of heat. A key feature of the cooling circuit with this cooling plate is its high efficiency. In an advantageous embodiment, the cooling plate may be disposed inside the housing. In another embodiment, the cooling plate may form a protective plate or cover for the housing.

[0015] Suitablely, a cooling plate can be geometrically positioned between the power electronics and the induction coil. Therefore, the cooling plate can absorb heat from both the power electronics and the induction coil independently, thus improving cooling.

[0016] According to an advantageous embodiment, at least one wall can be erected on the upper side of the cooling plate facing the power electronic device. This wall is thermally connected to the cooling plate and encloses a receiving area, which is open at its end away from the cooling plate and configured to receive at least one component of the power electronic device. The corresponding component of the power electronic device arranged in this receiving area can be cooled particularly effectively because heat can also be dissipated from the corresponding component through the wall. In particular, the corresponding component can be thermally connected to the corresponding wall. Suitably, multiple such receiving areas can be constructed on the upper side of the cooling plate, each containing at least one component of the power electronic device. The corresponding component of the power electronic device can extend through the open end of the corresponding receiving area into that receiving area.

[0017] According to an advantageous embodiment, the cooling plate may have at least one plate opening through which at least one attachment element of the induction coil passes, the at least one attachment element being configured for electrically connecting the induction coil to a power electronic device. This allows for a particularly compact structural form for the charger.

[0018] According to an advantageous embodiment, the charger may have a ferrite plate assembly disposed on or within a housing, the ferrite plate assembly being geometrically positioned between the induction coil and the cooling circuit. The ferrite plate assembly has multiple ferrite plates, each magnetically directed, thereby significantly improving the efficiency of induced energy transfer through the induction coil. Suitably, the induction coil may be thermally connected to the ferrite plate assembly, allowing the ferrite plates to absorb and dissipate heat from the induction coil.

[0019] According to a particularly advantageous embodiment, the ferrite plate assembly can be thermally connected to a cooling plate. Thus, heat generated in the induction coil during wireless charging can be transferred to and from the ferrite plate to the cooling plate.

[0020] According to an advantageous embodiment, the ferrite plate assembly may have at least one assembly opening through which at least one attachment element of the induction coil passes, the at least one attachment element being configured for electrically connecting the induction coil to a power electronics device. This measure results in a particularly compact structure for the charger.

[0021] A battery-electric motor vehicle according to the present invention includes a traction battery, a cooling device for cooling and supplying coolant, a charging socket for wired charging of the traction battery, a controller for controlling the charging process, and a charger of the type described above. In this vehicle, a coolant inlet interface and a coolant outlet interface are fluidly connected to the cooling device. Furthermore, a cable interface is electrically connected to the charging socket, a battery interface is electrically connected to the traction battery, and a control interface is electrically connected to the controller.

[0022] Other important features and advantages of the invention are apparent from the dependent claims, the drawings, and the description of the drawings based on the drawings.

[0023] It goes without saying that the features described above and below can be used not only in the combinations given, but also in other combinations or individually, without departing from the scope of the invention as defined by the claims. The components of a higher-level unit (e.g., apparatus, device, or component) mentioned above and below, even if individually indicated, may form individual members or parts of that unit or integrated regions or sections of that unit, even if this is not shown differently in the drawings. Attached Figure Description

[0024] Preferred embodiments of the present invention are shown in the accompanying drawings and explained in detail in the following description, wherein the same reference numerals denote the same or similar or functionally identical parts.

[0025] The attached figures schematically illustrate: Figure 1 An isometric view of the charger is shown. Figure 2 An exploded view of the charger is shown as an isometric view. Figure 3 This diagram shows a simplified circuit diagram of a battery-powered electric vehicle. Detailed Implementation

[0026] according to Figure 3 The battery-electric vehicle 1, symbolically shown by the frame, includes a traction battery 2, a cooling device 3 for cooling and supplying coolant, a charging socket 4 for wired charging of the traction battery 2, a controller 5 for controlling the charging process, and a charger 6. The charger 6 is configured as an on-board charger 7 and is therefore fixedly mounted on the vehicle 1. The charger 6 is also configured for wired and wireless charging of the traction battery 2 of the vehicle 1.

[0027] according to Figure 1 and Figure 2 The charger 6, configured as an on-board charger 7, includes a housing 8, which may suitably have an upper housing portion 9 and a lower housing portion 10. The upper and lower housing portions may be shell-shaped and can be fastened together to enclose the housing 8. The lower housing portion 10 is made of a material that does not shield electromagnetic fields, such as plastic. The charger 6 also has a power electronics device 11, which is concealed within the housing 8 and arranged inside the housing 8.

[0028] according to Figure 2 The charger 6 also includes an induction coil 12, which is arranged or mounted on or within the housing 8. In the illustrated embodiment, the induction coil 12 is arranged inside the lower portion 10 of the housing. The lower portion 10 of the housing is configured to protect the induction coil 12. The induction coil 12 is electrically connected to the power electronics 11. For this purpose, the induction coil 12 may have two attachment elements 13, 14, which are located within... Figure 2 The housing is exemplaryly configured as a rod and is arranged for electrical connection with the power electronics 11. In the illustrated embodiment, the lower housing 10 forms a cover or protective plate for the upper housing 9, such that when the lower housing 10 is fastened to the upper housing 9 to form the housing 8, Figure 1 In its assembled state, the upper part 9 of the housing is closed by the lower part 10 of the housing. In this case, the induction coil 12 is arranged inside the housing 8.

[0029] according to Figure 2 The charger 6 also has a cooling circuit 15, which in Figure 2 The diagram is simplified using dashed lines. The cooling circuit 15 is arranged inside the housing 8 and configured to guide the coolant and to cool the power electronics 11 and the induction coil 12.

[0030] according to Figure 1 and Figure 2 The charger 6 also has a cable interface 16, a battery interface 17, a control interface 18, a coolant inlet interface 19, and a coolant outlet interface 20 on the outside of the housing 8. The cable interface 16 is electrically connected to the power electronics 11 and is used to electrically connect the charger 6 to the charging socket 4 for wired charging of the traction battery 2. For this purpose, the cable interface 16 can be configured as a three-phase interface. Figure 3 In this configuration, cable interface 16 is electrically connected to charging socket 4 via corresponding connecting line 21. Battery interface 17 is electrically connected to power electronics 11 and is also used for electrical connection to traction battery 2. Figure 3 In this configuration, battery interface 17 is electrically connected to traction battery 2 via connecting line 22. Control interface 18 is electrically connected to power electronics 11 and is also used for electrical connection to controller 5. Figure 3 In this configuration, control interface 18 is electrically connected to controller 5 via control line 23. Coolant inlet interface 19 is used to supply coolant to cooling circuit 15 and is fluidly connected to cooling circuit 15 for this purpose. Figure 3 In this configuration, the cooling device 3 is fluidly attached to the coolant inlet port 19 via an inlet line 24. Suitably, the cooling device 3 may have a delivery device 25, particularly a pump, for driving the coolant, which may be suitably arranged in the inlet line 24. The coolant outlet port 20 is fluidly connected to the cooling circuit 15 and is used to discharge the coolant from the cooling circuit 15. Figure 3 The cooling device 3 is fluidly connected to the coolant outlet interface 20 via the return line 26.

[0031] according to Figure 1 and Figure 2 The charger 6 may also have an on-board electrical grid interface 27 disposed on the outside of the housing 8, which is electrically connected to the power electronics 11 and configured for use with... Figure 3 The symbolic representation is the onboard electrical connection 28 of the linear line section. According to... Figure 3 The vehicle-mounted electrical grid interface 27 can be electrically connected to the vehicle-mounted electrical grid 28 via the connecting line 29.

[0032] according to Figure 2The charger 6 may have a cooling plate 30, which is arranged flat and planar. The cooling plate 30 is disposed inside the housing 8 and / or between the upper housing portion 9 and the lower housing portion 10. A cooling circuit 15 is constructed in the cooling plate 30. For this purpose, the cooling plate 30 includes a channel system (not shown) that forms the cooling circuit 15. The cooling plate 30 is geometrically arranged in the housing 8 between the power electronics device 11 and the induction coil 12. The induction coil 12 is arranged flat and planar, and the cooling plate 30 extends parallel to the plane. In another embodiment (not shown), the cooling plate 30 may form a cover or protective plate for the upper housing portion 9, such that... Figure 1 In the assembled state, when the cooling plate 30 is fastened to the upper part 9 of the housing to form the housing 8, the upper part 9 of the housing is closed by the cooling plate 30. In this case, the induction coil 12 is arranged on the outside of the housing 8.

[0033] exist Figure 2 In the example, the cooling plate 30 has a plurality of walls 32 on its upper side 31 facing the power electronics device 11, each wall standing upright on the upper side 31 of the cooling plate 30, i.e., upright towards the power electronics device 11. The walls 32 are thermally connected to the cooling plate 30 and each encloses a receiving region 33. Here, the size and positioning of the receiving region 33 are configured or arranged complementary to the components of the power electronics device 11 (not shown). The receiving region 33 is configured to be open at its end away from the cooling plate 30 and is configured to receive at least one component of the power electronics device 11. In other words, the receiving region 33 is open upwards, such that, in the assembled state, the corresponding components of the power electronics device 11 are recessed from above into these receiving regions 33.

[0034] Suitably, the coolant inlet port 19 and the coolant outlet port 20 can be fixedly connected to the cooling plate 30 and fluidly connected to the cooling circuit 15 constructed in the cooling plate. Figure 2 The cooling plate 30 may have at least one plate opening 34, which is positioned and sized such that, in the assembled state of the charger 6, at least one of the attachment elements 13, 14 of the induction coil 12 passes through the corresponding plate opening 34.

[0035] according to Figure 2The charger 6 may also have a ferrite plate assembly 35, which is arranged or mounted on or within the housing 8, and geometrically positioned between the induction coil 12 and the cooling circuit 15 or cooling plate 30. The ferrite plate assembly 35 is here arranged flat and planar, and the cooling plate 30 extends parallel to the plane. The induction coil 12 is suitably thermally connected to the ferrite plate assembly 35. The ferrite plate assembly 35 is suitably thermally connected to the cooling plate 30 in that respect. The ferrite plate assembly 35 includes a plurality of individual ferrite plates 36, which are arranged side-by-side and may be individually arranged flat and planar. The ferrite plate assembly 35 may also have at least one assembly opening 37, the arrangement and size of which are configured such that, in the assembled state of the charger 6, at least one of the attachment elements 13, 14 of the induction coil 12 passes through the assembly opening 37.

[0036] exist Figure 1 and Figure 2 In the preferred embodiment shown, the ferrite plate assembly 35 is arranged inside the lower part 10 of the housing, and correspondingly inside the housing 8.

[0037] exist Figure 2 The illustrated embodiment also includes a recess 39 in the cooling circuit connection area 38 of the upper housing 9, which opens toward the lower housing 10, and the free inner cross-section of the recess is greater than the sum of the outer cross-sections of the coolant inlet port 19 and the coolant outlet port 20. Furthermore, according to... Figure 2 A sealing element 40 is arranged on the cooling plate 30, which is complementary to the notch 39. The coolant inlet port 19 and coolant outlet port 20 pass through the sealing element 40 and are fluidly connected to the cooling circuit 15. In the assembled state, the sealing element 40 closes the notch 39, wherein the sealing element 40 is pressed upward against the upper part 9 of the housing and downward against the lower part 10 of the housing, and is particularly sealingly connected to them.

[0038] List of reference numerals 1 Motor vehicles 2 Traction Battery 3. Cooling device 4. Charging socket 5 Controllers 6 Chargers 7. Car charger 8. Housing 9. Upper part of the shell 10. Lower part of the shell 11 Power Electronic Devices 12 Induction coils 13 Attachment Components 14 Attachment components 15 Cooling Circuit 16 Cable Interfaces 17 Battery Interface 18 Control Interface 19 Coolant inlet interface 20 Coolant outlet interface 21 Connection Line 22 Connection lines 23 Control circuit 24 Inflow lines 25 Conveying device 26 Return Line 27. Vehicle-mounted electrical grid interface 28. Vehicle-mounted electrical grid 29. Connection Lines 30 Cooling plate 31 upper side 32 wall 33 Accommodation Area 34-plate opening 35 Ferrite Plate Assembly 36 Ferrite Plates 37 Component openings 38 Cooling circuit connection area 39 Notch 40. Enclosed element.

Claims

1. A charger (6) for a battery-powered electric vehicle (1). in, The charger (6) is configured as an on-board charger (7), which is used for wired and wireless charging of the traction battery (2) of the motor vehicle (1). The charger (6) includes: Casing (8); Power electronic devices (11) arranged inside the housing (8); An induction coil (12) is arranged on or in the housing (8) and electrically connected to the power electronics (11). A cooling circuit (15) is arranged inside the housing (8) for guiding coolant and for cooling the power electronics (11) and the induction coil (12). A cable interface (16) arranged on the outside of the housing (8) and electrically connected to the power electronics (11) is provided for electrically connecting the charger (6) to a charging socket (4) of the motor vehicle (1) configured for wired charging. A battery interface (17) is arranged on the outside of the housing (8) and electrically connected to the power electronics (11), the battery interface being used for electrical connection to the traction battery (2); A control interface (18) is arranged on the outside of the housing (8) and electrically connected to the power electronics (11). The control interface is used to electrically connect to a controller (5) for controlling the charging process. A coolant inlet port (19) is disposed on the outside of the housing (8) and is fluidly connected to the cooling circuit (15), the coolant inlet port being used to supply the coolant to the cooling circuit (15). A coolant outlet port (20) is disposed on the outside of the housing (8) and is in fluid connection with the cooling circuit (15), the coolant outlet port being used to discharge the coolant from the cooling circuit (15).

2. The charger (6) according to claim 1. Its features are, The charger (6) has an on-board electrical grid interface (27) disposed on the outside of the housing (8) and electrically connected to the power electronics (11), the on-board electrical grid interface being used to electrically connect to the on-board electrical grid (28) of the motor vehicle (1).

3. The charger (6) according to any one of the preceding claims. Its features are, The charger (6) has a cooling plate (30) arranged on or in the housing (8), in which the cooling circuit (15) is constructed.

4. The charger (6) according to claim 3. Its features are, The cooling plate (30) is geometrically arranged in the housing (8) between the power electronics (11) and the induction coil (12).

5. The charger (6) according to claim 3 or 4. Its features are, At least one wall (32) is erected on the upper side (31) of the cooling plate (30) facing the power electronic device (11), the at least one wall being thermally connected to the cooling plate (30) and enclosing a receiving area (33), the receiving area being open at the end away from the cooling plate (30) and configured to receive at least one component of the power electronic device (11).

6. The charger (6) according to any one of claims 3 to 5. Its features are, The cooling plate (30) has at least one plate opening (34), through which at least one attachment element (13, 14) of the induction coil (12) passes, the at least one attachment element being used to electrically connect the induction coil (12) to the power electronics (11).

7. The charger (6) according to any one of the preceding claims. Its features are, The charger (6) has a ferrite plate assembly (35) disposed on or in the housing (8), the ferrite plate assembly being geometrically arranged between the induction coil (12) and the cooling circuit (15).

8. The charger (6) according to claims 3 and 7. Its features are, The induction coil (12) is thermally connected to the ferrite plate assembly (35). The ferrite plate assembly (35) is thermally connected to the cooling plate (30).

9. The charger (6) according to claim 7 or 8. Its features are, The ferrite plate assembly (35) has at least one assembly opening (37) through which at least one attachment element (13, 14) of the induction coil (12) passes, the at least one attachment element being used to electrically connect the induction coil (12) to the power electronics device (11).

10. A battery-powered electric vehicle (1), comprising: Traction battery (2); Cooling device for cooling and conveying coolant (3); A charging socket (4) for wired charging of the traction battery (2). Controller (5) for controlling the charging process; Charger (6) according to any one of the preceding claims. The coolant inlet (19) and coolant outlet (20) are fluidly connected to the cooling device (3). The cable interface (16) is electrically connected to the charging socket (4). The battery interface (17) is electrically connected to the traction battery (2). The control interface (18) is electrically connected to the controller (5).

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