Arrangement for charging an energy storage device of an electrically powered vehicle and method

Abstract

Arrangement for charging an energy storage device of an electrically powered vehicle, wherein a contactless energy transfer to the vehicle is carried out by inductively coupling a primary coil (4) to a secondary coil provided in the vehicle, by allowing the primary winding (41) to be inserted into a recess (5) surrounded by the secondary winding (40), wherein the primary coil (4) is incorporated in a unit which is essentially in the form of a fuel nozzle for refueling a vehicle with a gasoline engine, wherein a sensor is provided for detecting the insertion of the primary coil (4) and means for contactless data transmission are provided, wherein the primary coil (4) has a cylindrical outer shape, wherein the axial length of the cylinder exceeds twice the diameter of the cylinder, characterized by the fact that the primary coil (4) has a ferrite core (42), wherein a retaining tube part (46) or a retaining solid tube part is attached to the housing part (3), onto which the ferrite core (42), in particular its ferrite rings, is placed, wherein the primary coil (4) is attached to a housing part (3) to which a retaining bracket is also attached and into which the primary conductor cable (1) supplying the primary winding (41) of the primary coil (4) is also inserted and wherein the primary coil (4) and the entry direction of the primary conductor cable (1) into the housing part (3) have an angle to each other between 90° and 180°, i.e. do not run parallel.

Description

[0001] Arrangement for charging an energy storage device of an electrically powered vehicle and method Description:

[0002] The invention relates to an arrangement for charging an energy storage device of an electrically powered vehicle and a method.

[0003] Electrically powered vehicles have a battery that is usually charged using a charger. The charger is located either outside or inside the vehicle.

[0004] US patent 5,907,231 A discloses a magnetic coupling arrangement for charging an electric vehicle as the closest prior art.

[0005] An inductive coupler is known from DE 30 32 319 A1.

[0006] A connector is known from DE 196 21 003 A1.

[0007] A fuel nozzle with a discharge pipe is known from DE 199 02 013 A1.

[0008] The invention is therefore based on the objective of increasing the safety of people when loading the vehicle.

[0009] According to the invention, the problem is solved in the arrangement according to the features specified in claim 1 and in the method according to the features specified in claim 11.

[0010] Important features of the invention in the arrangement for charging an energy storage device of an electrically operated vehicle are that contactless energy transfer to the vehicle is carried out by inductively coupling a primary coil to a [missing information] in the [missing information] wherein the primary coil is received in a unit which essentially serves in the form of a fuel nozzle for refueling a vehicle with a gasoline engine,

[0011] in particular wherein the unit comprises a retaining bracket which is attached to a housing part of the unit to which the cone-shaped primary coil is also attached.

[0012] An advantage of this design is the galvanic isolation, which provides better protection for the operator. Furthermore, the primary component is intuitively recognized as a fuel nozzle, similar to those used in gasoline-powered vehicles, and is therefore inserted into a recess on the vehicle body for charging, which is analogous to refueling a gasoline-powered vehicle. This recess resembles the fuel filler neck of a gasoline-powered vehicle.

[0013] Important features of the arrangement for charging an energy storage device of an electrically operated vehicle according to claim 2 are that a primary winding can be inductively coupled to a secondary winding by being able to insert the primary winding into a recess surrounded by the secondary winding, The primary coil is shaped like a cone, and in particular essentially cylindrically. This design offers the advantage of easy and simple insertion.

[0014] According to the invention, the primary coil is attached to a housing part to which a retaining bracket is also connected and into which the primary conductor cable supplying the primary winding of the primary coil is inserted. An advantage of this is that a central part is provided to which not only the primary coil is attached, but also at least one end of the retaining bracket and into which the primary conductor cable is inserted.

[0015] According to the invention, the primary coil and the entry direction of the primary conductor cable into the housing part form an angle to each other between 90° and 180°, i.e., they are not parallel. In particular, the pin and the entry direction of the primary conductor cable into the housing part form an obtuse angle to each other, specifically an angle between 90° and 180°, i.e., they are not parallel and do not form an acute angle of less than 90°, and the retaining bracket is provided on the outside, i.e., in the region of the outer angle greater than 180°, particularly wherein the retaining bracket is provided in the plane spanned by the pin and the entry direction. It is advantageous that the appearance resembles the shape of a fuel nozzle for refueling a motor vehicle, and thus the insertion into a recess resembling a fuel tank opening is intuitively clear to the operator.

[0016] In a preferred embodiment, the primary coil has a ferrite core, which is either a single piece or composed of ferrite cores. The advantage here is that standard components can be used for small production runs, while a single-piece design is feasible for mass production.

[0017] In an advantageous embodiment, the primary winding of the primary coil is wound onto the ferrite core, with the ferrite core extending radially from the axial ends of the primary winding into the radial region of the primary winding. In particular, the ferrite core includes an axial region that is radially recessed to accommodate the primary winding. An advantage of this design is that a dogbone-shaped ferrite core is thus provided, onto which the winding can be easily and securely applied.

[0018] Similarly, the secondary winding can be inserted into a secondary-side ferrite core, particularly as a ring winding, which has an axial section that is tubular in shape and whose axial sections adjoining the winding extend radially into the radial section of the secondary winding. In other words, the ferrite core is essentially a body of revolution generated by rotating a U-shaped element around the winding axis of the secondary winding, with the legs of the U pointing radially inwards.

[0019] In a preferred design, the primary and secondary windings form a ring winding. This design offers the advantage of simple and cost-effective manufacturing.

[0020] In an advantageous embodiment, the ferrite core is a body of revolution that can be produced by rotating a U-shaped shape whose legs are radially oriented. The advantages of this design are that it allows for simple manufacturing and easy axial fixation of the winding.

[0021] In an advantageous embodiment, a sensor is provided for detecting the insertion of the primary coil, in particular wherein the sensor is a reed contact triggered by a permanent magnet. The advantage here is that it is cost-effective and reliable detection can be ensured even with long service life and contamination.

[0022] In an advantageous embodiment, means for contactless data transmission are provided, in particular via infrared or radio. The advantage here is that interference-free data transmission is enabled, especially in contrast to the modulation of higher-frequency current components onto the primary current.

[0023] In an advantageous embodiment, the primary coil features jacket cooling; in particular, an inlet and an outlet are provided on the jacket of the primary coil. The advantage here is that high power can be transmitted inductively and the connector can be cooled.

[0024] In an advantageous embodiment, a retaining tube or a solid tube is attached to the housing part, onto which the ferrite core, in particular its ferrite rings, are placed. The advantage here is that simple manufacturing is possible, since only ferrite cores need to be placed onto a tube-like or pin-like part and, if necessary, glued in place.

[0025] Key features of the method for operating an arrangement are that the insertion of the primary coil into the secondary coil is detected by means of a sensor, the sensor signal of which enables or activates an electronic charging circuit in the vehicle, so that the charging process is carried out. wherein, after release and / or switching on, corresponding information is transmitted contactlessly, in particular via radio or infrared, to an electronic arrangement connected to the primary coil, so that the primary current is only switched on after receiving this information or is brought to the current value specified for charging the energy storage device.

[0026] The advantage here is that the vehicle's electronic charging circuit can be "woken up" after the primary part is plugged in. However, this requires the sensor to be operational, meaning it needs a power supply to generate the sensor signal. Alternatively, a sensor without a power supply could be used, such as a Wiegand sensor, whose signal contains enough energy to power an electronic circuit.

[0027] In an advantageous embodiment, the energy storage device is a high-voltage battery voltage, in particular with a battery voltage of more than 200 volts, Before receiving the information, a primary current is impressed into the primary winding that is at least ten times lower than the value specified for charging the energy storage device, or a primary current is impressed that enables the charging of a low-voltage battery, for example, a 12-volt or 24-volt battery, provided in the vehicle in addition to the energy storage device. The advantage here is that the drive system can be powered from the energy storage device, and the low-voltage battery provides emergency power for the vehicle's control electronics even if the energy storage device fails or is discharged. If the low-voltage battery should also be discharged, it could be recharged by generating the small charging current required for this purpose, i.e., at low voltage. Thus, safety is ensured, and the low-voltage battery can be recharged.Once sufficiently charged, the other electronic circuitry can be activated and / or switched on, which then wirelessly reports this state back to the electronic circuit supplying the primary conductor. In response, the current and voltage are increased to such an extent that the energy storage device is charged at a high voltage, i.e., more than 100 or 200 volts, or with a correspondingly high current.

[0028] Further advantages arise from the sub-claims.

[0029] The invention will now be explained in more detail with the help of illustrations: In Fig. Figure 1 shows the primary and secondary side connector parts in the extended position. In Fig. Figure 2 also shows a withdrawn state. In Fig. Figure 3 shows the plugged-in state. In Fig. 4 is one to Fig. 3 proper cut shown.

[0030] In the plugged-in state, a primary winding 41 of the primary-side connector part is inductively connected to a secondary winding 40 of the secondary-side connector part.

[0031] The primary current is supplied to the primary winding 41 via the conductors enclosed by the primary conductor cable. This winding is wound on a ferrite core 42, which ideally or essentially is designed as a body of revolution created by rotating a U-shaped element spaced apart from the axis of rotation, the legs of which point radially away from the axis of rotation.

[0032] For quick and easy production, the ferrite core 42 can be constructed from ferrite rings that are placed onto the holder tube part 46, so that the shape of the described body of revolution is only approximately achieved. Alternatively, the ferrite core 42 can also be manufactured in one piece.

[0033] The winding axis of the primary winding is parallel to the aforementioned axis of rotation and is therefore, so to speak, contained in a radial depression of the ferrite core.

[0034] The ferrite core 42 is provided around a retaining tube part 46, thus surrounding it, and is then connected to a housing part 3 axially spaced from the primary winding, on which a retaining bracket 2 is provided.

[0035] The primary-side connector part is inserted into a recess 5 of the secondary-side connector part, thereby achieving very good inductive coupling of the primary winding 41 with the secondary winding 40.

[0036] A medium-frequency current, in particular with a frequency between 10 and 500 kHz, is impressed into the primary winding 41 via the primary conductor cable 1. A capacitor is connected in series or parallel to the secondary winding 40 such that the associated resonant frequency essentially corresponds to the medium frequency.

[0037] The primary-side connector part has an overall appearance that is modeled on a fuel filler neck of a refueling system for cars, i.e., road-legal gasoline-powered motor vehicles.

[0038] This makes it quick and easy to use for charging an electric vehicle. The operator, familiar with refueling a gasoline-powered vehicle, immediately recognizes the connector's function. They instinctively know that the connector part must be inserted into the corresponding recess on the electric vehicle's body.

[0039] The secondary-side connector part has a flange for attachment to the body of the electric vehicle. This creates a certain external resemblance to the fuel filler neck of a gasoline-powered vehicle, making its use intuitively clear.

[0040] Despite the good inductive coupling, heat generation in the connector is unavoidable. Therefore, an inlet 47 for a cooling medium, in particular water or air, is provided, which opens into channels that run circumferentially and lead to an outlet 7 for the cooling medium. Thus, the connector can be connected to the vehicle's cooling circuit. Preferably, the cooling medium in this cooling circuit is driven by a pump.

[0041] The secondary-side current is routed out via cable 8 and directed to an electronic circuit that makes the vehicle's energy storage device, in particular the battery, chargeable.

[0042] The secondary winding 40 is provided in the ferrite core 43, whereby the essential part of the magnetic field can be guided from the ferrite core 43 to the ferrite core 42 via a small air gap and thus a very strong coupling can be achieved.

[0043] At the axial end region of the primary coil and its ferrite core, a primary-side electronic arrangement 45 is provided, which has means for data exchange with a secondary-side electronic arrangement 46 located at the end of the recess 5 in a contactless manner, for example via infrared, radio, or ultrasound. In this way, data can be transmitted with minimal or no interference, since this data transmission can be carried out independently of the inductive energy transfer between the primary and secondary coils.

[0044] Furthermore, a sensor is provided on the primary side, enabling detection of the primary-side connector part after it has been fully inserted. For example, a reed contact can be used for this purpose, which makes a permanent magnet on the primary-side connector detectable when it enters the sensor's sensitive area. Alternative sensors, such as proximity sensors or similar devices, can also be used.

[0045] Thus, after detection of the primary-side connector part, it is possible to switch on the secondary-side electronic circuits.

[0046] In further embodiments of the invention, the retaining tube part 46 is made of aluminum or plastic. A solid part can also be used instead of a tube part. Reference symbol list 1 Primary conductor cable 2 retaining brackets 3 Housing part 4 Primary coil 5 Exclusion 6 Housing part 7 Outlet for cooling medium 8 cables for secondary-side power 40 Secondary winding 41 Primary winding 42 Ferrite core 43 Ferrite core 44 secondary-side electronic arrangement 45 primary-side electronic arrangement 46 Holder tube part 47 Inlet for cooling medium

Claims

[1] Arrangement for charging an energy storage device of an electrically powered vehicle, wherein a contactless energy transfer to the vehicle is carried out by inductively coupling a primary coil (4) to a secondary coil provided in the vehicle, by allowing the primary winding (41) to be inserted into a recess (5) surrounded by the secondary winding (40), wherein the primary coil (4) is incorporated in a unit which is essentially in the form of a fuel nozzle for refueling a vehicle with a gasoline engine, wherein a sensor is provided for detecting the insertion of the primary coil (4) and means for contactless data transmission are provided, wherein the primary coil (4) has a cylindrical outer shape, wherein the axial length of the cylinder exceeds twice the diameter of the cylinder, characterized by , that the primary coil (4) has a ferrite core (42), wherein a retaining tube part (46) or a retaining solid tube part is attached to the housing part (3), onto which the ferrite core (42), in particular its ferrite rings, is placed, wherein the primary coil (4) is attached to a housing part (3) to which a retaining bracket is also attached and into which the primary conductor cable (1) supplying the primary winding (41) of the primary coil (4) is also inserted and wherein the primary coil (4) and the entry direction of the primary conductor cable (1) into the housing part (3) have an angle to each other between 90° and 180°, i.e. do not run parallel. [2] Arrangement according to claim 1, characterized by , that the primary coil (4) is shaped like a cone, in particular essentially cylindrically. [3] Arrangement according to at least one of the preceding claims, characterized by, that the pin and the entry direction of the primary conductor cable (1) into the housing part (3) have an obtuse angle to each other, in particular an angle between 90° and 180°, i.e. not parallel and not an acute angle of less than 90°, and the retaining bracket (2) is provided on the outside, i.e. in the area of ​​the outside angle of more than 180°, in particular wherein the retaining bracket (2) is provided in the plane spanned by the pin and the direction of entry. [4] Arrangement according to at least one of the preceding claims, characterized by , that the ferrite core (42) is made of one piece or is composed of ferrite cores. [5] Arrangement according to at least one of the preceding claims, characterized by, that the primary winding (41) of the primary coil (4) is wound onto the ferrite core (42), wherein the ferrite core (42) extends radially from the axial ends of the primary winding (41) into the radial area of ​​the primary winding (41). [6] Arrangement according to at least one of the preceding claims, characterized by , that the ferrite core (42) includes an axial area which is radially recessed to accommodate the primary winding (41). [7] Arrangement according to at least one of the preceding claims, characterized by , that the primary winding (41) and secondary winding (40) form a ring winding. [8] Arrangement according to at least one of the preceding claims, characterized by , that the ferrite core (42) is a body of revolution which can be produced by rotating a U whose legs are radially oriented. [9] Arrangement according to at least one of the preceding claims, characterized by , that the sensor for detecting the insertion of the primary coil (4) is a reed contact triggered by a permanent magnet, and / or that the means are suitable for contactless data transmission via infrared or radio. [10] Arrangement according to at least one of the preceding claims, characterized by , that the primary coil (4) has a jacket cooling system, in particular an inlet (47) and an outlet (7) are provided on the jacket of the primary coil (4). [11] Method for operating an order according to at least one of the preceding claims, characterized by , that the insertion of the primary coil (4) into the secondary coil is detected by means of a sensor, the sensor signal of which enables or activates an electronic charging circuit in the vehicle, so that the charging process is carried out, wherein, after release and / or switching on, corresponding information is transmitted contactlessly, in particular via radio or infrared, to an electronic arrangement (45) connected to the primary coil (4), so that the primary current is only switched on after receipt of this information or is brought to the current value specified for charging the energy storage device. [12] Method according to claim 11, characterized by , that The energy storage device is a high-voltage battery, especially with a battery voltage of more than 200 volts. and before receiving the information, a primary current is impressed into the primary winding (41) which is at least ten times lower than the value specified for charging the energy storage device, or such a primary current is impressed that enables the charging of a low-voltage battery provided in the vehicle in addition to the energy storage device, for example a 12-volt or 24-volt battery.

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