Disconnect switch position indicator for an electric vehicle

Abstract

Arrangement, comprehensive: a disconnect switch (56) and a position indicator (60, 60A) configured to engage with the disconnect switch (56) when the disconnect switch (56) is in a set position and to be released from the disconnect switch (56) when the disconnect switch (56) is in a detached position, comprising a clip extending from a base (84) of the position indicator (60, 60A), wherein the clip engages with a disconnect switch surface facing away from the base (84) when the disconnect switch (56) is in the set position, and wherein the clip makes contact with a disconnect switch surface facing towards the base (84) when the disconnect switch (56) is in a detached position.

Description

BACKGROUND

[0001] This disclosure relates generally to a disconnect switch, and in particular to an indicator for checking the disconnect switch position.

[0002] In general, electric vehicles differ from conventional motor vehicles because electric vehicles are selectively powered using one or more battery-powered electric motors. Conventional motor vehicles, on the other hand, rely exclusively on an internal combustion engine to propel the vehicle. Electric vehicles can use electric motors instead of, or in addition to, the internal combustion engine.

[0003] Examples of electric vehicles include hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), fuel cell vehicles, and battery electric vehicles (BEVs). An electric vehicle's powertrain typically includes a battery that stores electrical energy to power the electric motor. The battery can be charged before use and can be recharged during driving through regenerative braking or by an internal combustion engine.

[0004] Electric vehicles are equipped with disconnect switches. During normal operation, the disconnect switch is set to closed. Opening the disconnect switch may be necessary, for example, for vehicle maintenance. Verifying that the disconnect switch is set and closed can be difficult. In some cases, the disconnect switch may appear closed but not actually be set. In such cases, road vibrations can cause the disconnect switch to open unintentionally. KR 10 2010 0 138 072 A discloses a device for coupling electric current. SUMMARY

[0005] An improvement in the prior art is achieved by an arrangement according to claim 1, an electric vehicle arrangement according to claim 6, and a method according to claim 12. An arrangement according to an exemplary aspect of the present disclosure includes, inter alia, a position indicator configured to engage a disconnect switch when the disconnect switch is in a set position and to release the disconnect switch when the disconnect switch is in a disengaged position.

[0006] In another example of the above arrangement, the arrangement includes a clip extending from a base of the position indicator. The clip engages a disconnect switch surface facing away from the base when the disconnect switch is in the set position. The clip is intended to make contact with a disconnect switch surface facing the base when the disconnect switch is in a disengaged position.

[0007] In another example of any of the above arrangements, the disconnect switch surface is a surface of a swivel handle.

[0008] In another example of any of the above arrangements, the swivel handle surface includes a pin surface of the swivel handle.

[0009] In another example of any of the above arrangements, a mounting tab extends from the base opposite the clip.

[0010] In another example of any of the foregoing arrangements, the clip is a first clip and the arrangement further comprises a second clip extending from the base at an end opposite to the base from the first clip, so that the second clip engages with the disconnect switch.

[0011] In another example of any of the above arrangements, the first clip is configured to rotate around the second clip when the latter moves to a snap-in position.

[0012] An electric vehicle arrangement according to another exemplary aspect of the present disclosure includes a disconnect switch within an electric vehicle powertrain. The disconnect switch can be moved from a disengaged position to a set position and from the set position to the disengaged position. A position indicator is configured to engage the disconnect switch in the set position and to disengage the disconnect switch in the disengaged position.

[0013] In another example of the above arrangement, the disconnect switch is opened to electrically disconnect sections of an electric vehicle powertrain and closed to electrically connect sections of the electric vehicle powertrain.

[0014] In another example of any of the above arrangements, the disconnect switch is closed in the set position and open or closed in the removed position.

[0015] In another example of any of the above arrangements, several high-voltage contactors of the electric vehicle powertrain are open when the disconnect switch is open, and several high-voltage contactors of the electric vehicle powertrain are closed when the disconnect switch is closed.

[0016] In another example of any of the above arrangements, the disconnect switch includes a first color and the position indicator includes a second color that is different from the first color.

[0017] In another example of any of the foregoing arrangements, the disconnect switch includes a handle that pivots or slides to move the disconnect switch from an unmounted to a mounted position. The disconnect switch is set when it is in the mounted position.

[0018] In another example of any of the above arrangements, the electric vehicle is a hybrid electric vehicle.

[0019] A method for verifying that a disconnect switch is set according to yet another exemplary aspect of the present disclosure comprises indicating that the disconnect switch is set by using a position indicator that selectively engages in the disconnect switch.

[0020] In another example of the above procedure, the procedure involves preventing the position indicator from locking into the disconnect switch, except when the disconnect switch is in a set position.

[0021] In another example of any of the foregoing methods, the method involves pivoting and moving a handle of the disconnect switch to move the disconnect switch from a detached position to a set position.

[0022] In another example of any of the foregoing methods, the method involves engaging the disconnect switch handle with the position indicator. In another example of any of the foregoing methods, the method involves a position indicator clip engaging with a disconnect switch surface facing away from a base of the position indicator when the disconnect switch is in the set position, the clip contacting a disconnect switch surface facing the base when the disconnect switch is in a retracted position. In another example of any of the foregoing methods, the method involves pivoting the position indicator to engage with the surface facing away from the base and making contact with the surface facing the base. DESCRIPTION OF THE FIGURES

[0023] The various features and advantages of the disclosed examples will be apparent to a person skilled in the art from the detailed description. The drawings appended to the detailed description can be briefly described as follows.

[0024] They show: Fig. 1 a schematic view of an exemplary electric vehicle powertrain; Fig. 2 a perspective view of a powertrain disconnect switch made of Fig. 1 in a detached position; Fig. 3 a perspective view of the disconnect switch Fig. 2, which was moved closer to a set position; Fig. 4. Turn off the disconnect switch Fig. 3, which is closer to the set position than the disconnect switch Fig. 3 was moved; Fig. 5. Turn off the disconnect switch Fig. 2 in the set position; Fig. 6 A perspective view of a position indicator that is in the disconnect switch in the off position Fig. 5 clicks into place; Fig. 7 the position indicator, which is in the off position with the disconnect switch Fig. 4 is used; Fig. 8 a section view along line 8-8 from Fig. 6; Fig. 9 another exemplary position indicator, which is in the off position with the disconnect switch Fig. 4 is used. DETAILED DESCRIPTION

[0025] Fig. Figure 1 schematically shows a powertrain 10 of an electric vehicle. Although a hybrid electric vehicle (HEV) is depicted, it will be understood that the concepts described herein are not limited to HEVs and could be extended to other electrified vehicles, including, but not limited to, plug-in hybrid electric vehicles (PHEVs) and battery electric vehicles (BEVs).

[0026] In one embodiment, the powertrain 10 is a power-split powertrain system employing a first drive system and a second drive system. The first drive system comprises a combination of a motor 14 and a generator 18 (i.e., a first electric machine). The second drive system comprises at least one electric motor 22 (i.e., a second electric machine), the generator 18, and a battery 24. In this example, the second drive system is considered an electric drive system of the powertrain 10. The first and second drive systems generate torque to drive one or more sets of vehicle drive wheels 28 of the electric vehicle.

[0027] The motor 14, which in this example is an internal combustion engine, and the generator 18 can be connected by a power transmission unit 30, such as a planetary gear set. Of course, other types of power transmission units are possible, including other gear sets and transmissions that can be used to connect the motor 14 to the generator 18. In a non-limiting embodiment, the power transmission unit 30 is a planetary gear set comprising a ring gear 32, a sun gear 34, and a carrier assembly 36.

[0028] The generator 18 can be driven by the motor 14 via the power transmission unit 30 to convert kinetic energy into electrical energy. Alternatively, the generator 18 can function as an electric motor to convert electrical energy into kinetic energy, thereby outputting torque to a shaft 38 connected to the power transmission unit 30. Since the generator 18 is operationally connected to the motor 14, the speed of the motor 14 can be controlled by the generator 18.

[0029] The ring gear 32 of the power transmission unit 30 can be connected to a shaft 40, which is connected to the vehicle drive wheels 28 by a second power transmission unit 44. The second power transmission unit 44 can have a gear set with multiple gears 46. Other power transmission units are also suitable. The gears 46 transmit torque from the motor 14 to a differential 48 to provide traction to the vehicle drive wheels 28. The differential 48 can have multiple gears that enable the transmission of torque to the vehicle drive wheels 28. In this example, the second power transmission unit 44 is mechanically coupled to an axle 50 via the differential 48 to distribute torque to the vehicle drive wheels 28.

[0030] The electric motor 22 (i.e., the second electric machine) can also be used to drive the vehicle's drive wheels 28 by outputting torque to a shaft 52, which is also connected to the second power transmission unit 44. In one embodiment, the electric motor 22 and the generator 18 are part of a regenerative braking system in which both the electric motor 22 and the generator 18 are used as electric motors to output torque. For example, the electric motor 22 and the generator 18 can output electrical power to the battery 24.

[0031] Battery 24 is an exemplary type of electric vehicle battery arrangement. Battery 24 can be a high-voltage battery capable of supplying electrical power to operate the electric motor 22 and the generator 18. Other types of energy storage and / or output devices can also be used with the electric vehicle, which has the powertrain 10.

[0032] A disconnect switch 56 is used to selectively disconnect the battery 24 from other sections of the powertrain 10. The disconnect switch 56 can be located in various positions within the vehicle, including areas near the battery 24. In other examples, the disconnect switch 56 can be used to electrically disconnect other sections of the powertrain 10.

[0033] The disconnect switch 56 can be closed or open. When it is closed, the battery 24 is electrically connected to the other sections of the powertrain 10. When it is open, the battery 24 is electrically disconnected from the other sections of the powertrain 10. When the disconnect switch 56 is closed, a high-voltage interlock loop and the high-voltage contactors of the powertrain 10 are closed. When the disconnect switch 56 is open, the high-voltage interlock loop and the high-voltage contactors are open. In some examples, the disconnect switch 56, transitioning from closed to open, triggers a warning, such as an on-board diagnostic code, which is displayed in the vehicle.

[0034] Generally, when closed, the disconnect switch 56 is set in the drive train 10. Releasing the disconnect switch 56 then causes the disconnect switch 56 to open.

[0035] During the assembly of the drive train 10, the disconnect switch 56 should be installed within the drive train 10 in the assembly line. Installing the disconnect switch 56 ensures that it remains closed during operation of the drive train 10. Installing the disconnect switch 56 prevents it from unintentionally moving from the closed to the open position.

[0036] If maintenance of the drive train 10 is required, the mechanic can disconnect the disconnect switch 56 and move the disconnect switch from the closed to the open position.

[0037] In some examples, setting the disconnect switch 56 is not required to close it. However, if the disconnect switch 56 is set, it may slide or otherwise move from the closed to the open position when such movement is undesired, for example, when the vehicle is moving. That is to say, when the disconnect switch 56 is set, it will not move from the closed to the open position when such a position is undesired. When the disconnect switch 56 is not set, it may move from the closed to the open position when such a position is undesired.

[0038] Setting the disconnect switch 56 during assembly is typically desirable, but verifying that the disconnect switch 56 is set is difficult. The exemplary drive train 10 has a position indicator 60 which is used to verify that the disconnect switch 56 is set.

[0039] With reference to Fig. 2 to 5, the exemplary disconnect switch 56 has a handle 64 or cam lever which is pivotably attached to the base 68 in order to move the disconnect switch 56 away from the uninsulated and open ( Fig. 2) to the set and closed ( Fig. 5) To move position. Starting from the position from Fig. 2 includes moving the disconnect switch 56 to a set and closed position, pivoting the handle 64 in a direction P with respect to the base 68, until the handle 64 is in the position from Fig. 4. Then the handle 64 slides in a direction D out of the in Fig. 4 positions shown are compared to the set position. Fig. 5.

[0040] Although the disconnect switch 56 can be closed when the disconnect switch 56 is, for example, in the position from Fig. If position 4 is reached, the disconnect switch 56 will not be closed and set until the disconnect switch 56 is in the open position. Fig. 5 is located.

[0041] In the position from Fig. 4. The disconnect switch 56 can move unintentionally from the closed to the open position. Setting the disconnect switch 56, as described in Fig. As shown in Figure 5, it prevents unwanted movement from the closed to the open position.

[0042] With reference to Fig. 6 is a position indicator 60 configured to intervene in the disconnect switch 56 when the disconnect switch 56 is set, as in Fig. Figure 5 shows that if the disconnect switch 56 is not set, the exemplary position indicator 60 cannot be properly secured to or locked into the disconnect switch 56. The exemplary position indicator 60 engages a portion of the handle 64 when secured to the disconnect switch 56.

[0043] Observing the position indicator 60 on the disconnect switch 56 confirms that the disconnect switch 56 is set and, for example, is not in the position of Fig. 4. The position indicator 60 and the disconnect switch 56 can be made of contrasting colors to facilitate identification that the position indicator 60 is secured to the disconnect switch. The position indicator 60 and the disconnect switch 56 together form a disconnect switch assembly.

[0044] With reference to Fig. 7 and Fig. Figure 8 shows that the position indicator 60 has a first clip 72, a second clip 76, and a mounting tab 80 extending from the base 84. To install the position indicator 60, the second clip 76 is positioned under a lip 88 of the disconnect switch 56. The position indicator 60 is then rotated in the direction P, so that the first clip 72 moves around the second clip 76 and into a position that engages with the handle 64. The tab 80 extends from the base opposite the first clip 72. During installation, a user can grasp the tab 80 to rotate the position indicator 60.

[0045] If the disconnect switch 56 is not in the set position of Fig. 5 and Fig. 6, the first clip 72 comes into contact with a surface 92 of the handle 64, as shown in Fig. 7 shown. When the disconnect switch 56 is in the set position from Fig. 5 and Fig. At position 6, a groove 96 of the first clip 72 receives a pin 100 extending from the joint handle 64. In some examples, the position indicator 60 comprises a polyvinyltoluene material to facilitate bending of the first clip 72 during assembly.

[0046] In order for the pin 100 to be inserted into the groove 96 and the second clip 76 to be inserted behind the lip 88, the exemplary position indicator 60 must be in the set position. As will be appreciated, the position indicator 60 can only be mounted when the disconnect switch 56 is in the set position. If the disconnect switch 56 is not in the set position, the position indicator 60 cannot be secured and may fall off the disconnect switch 56. The position indicator 60, when not secured to the disconnect switch 56, provides a visual indication that the disconnect switch 56 is not set.

[0047] A surface of the pin 100, which points away from the base 84, comes into contact with the first clip 72 when the position indicator 60 is engaged in the disconnect switch 56. The contact between the first clip 72 and the surface 92, which points towards the base 84, prevents the disconnect switch 56 from engaging in the unengaged state (i.e., not engaged).

[0048] The exemplary position indicator 60 has alignment ribs 104 for engaging with opposite sides of the disconnect switch 56. The position indicator 60 may have a window 108 to display information about the disconnect switch 56, such as text information printed on the disconnect switch 56. Support ribs 112 extend from the base 84 of the disconnect switch 56 to the tab 80. The support ribs 116 also extend from the base 84 to the second clip 76.

[0049] With reference to Fig.9 Another exemplary position indicator 60A may have two first clips 72' spaced apart from each other. The two first clips 72' engage in a surface 120 of the disconnect switch opposite a base 84' of the position indicator 60'. The position indicator 60A can only engage in the disconnect switch 56 when the disconnect switch 56 is in the set position.

[0050] The foregoing description is exemplary, not limiting. Variations and modifications of the disclosed examples may be apparent to a person skilled in the art without thereby deviating from the basis of this disclosure. Therefore, the scope of legal protection afforded by this disclosure can only be determined and examined with reference to the following claims.

Claims

[1] Arrangement, comprehensive: a disconnect switch (56) and a position indicator (60, 60A) configured to engage with the disconnect switch (56) when the disconnect switch (56) is in a set position and to be released from the disconnect switch (56) when the disconnect switch (56) is in a detached position, comprising a clip extending from a base (84) of the position indicator (60, 60A), wherein the clip engages with a disconnect switch surface facing away from the base (84) when the disconnect switch (56) is in the set position, and wherein the clip makes contact with a disconnect switch surface facing towards the base (84) when the disconnect switch (56) is in a detached position. [2] Arrangement according to claim 1, wherein the disconnect switch surface is a swivel handle surface. [3] Arrangement according to claim 1, comprising a mounting tab (80) extending from the base (84) opposite the clip. [4] Arrangement according to claim 1, wherein the clip is a first clip (72) and the arrangement further comprises a second clip (76) extending from the base (84) at an end opposite the base (84) from the first clip (72), wherein the second clip (76) engages with the disconnect switch (56). [5] Arrangement according to claim 4, wherein the first clip (72) is configured to rotate about the second clip (76) when it moves to a snap-in position. [6] Electric vehicle arrangement, comprising: a disconnect switch (56) within an electric vehicle powertrain (10), wherein the disconnect switch (56) can be moved from a remote position to a set position and from the set position to the remote position; and a position indicator (60, 60A) configured to engage in the disconnect switch (56) in the set position and to disconnect the disconnect switch (56) in the removed position, wherein the disconnect switch (56) comprises a handle (64) which pivots and slides to move the disconnect switch (56) from an unmounted position to a mounted position, wherein the disconnect switch (56) is set in the mounted position. [7] Arrangement according to claim 6, wherein the disconnect switch (56) is open to electrically disconnect sections of an electric vehicle powertrain (10) and is closed to electrically connect sections of the electric vehicle powertrain (10). [8] Arrangement according to claim 7, wherein the disconnect switch (56) is closed in the set position and is open or closed in the removed position. [9] Arrangement according to claim 6, wherein several high-voltage contactors of the electric vehicle powertrain (10) are open when the disconnect switch (56) is open, and several high-voltage contactors of the electric vehicle powertrain (10) are closed when the disconnect switch (56) is closed. [10] Arrangement according to claim 6, wherein the disconnect switch (56) comprises a first color and the position indicator (60, 60A) comprises a second color which is different from the first color. [11] Arrangement according to claim 6, wherein the electric vehicle is a hybrid electric vehicle. [12] Method for verifying that a disconnect switch (56) is installed, comprising: using the position indicator (60, 60A) to indicate that the disconnect switch (56) is set, which selectively engages with the disconnect switch (56), the pivoting and sliding of a handle (64) of the disconnect switch (56) to move the disconnect switch (56) from a detached position to a set position. [13] Method according to claim 12, comprising preventing the position indicator (60, 60A) from locking into the disconnect switch (56), except when the disconnect switch (56) is in the set position. [14] Method according to claim 12, comprising engaging the disconnect switch handle (64) with the position indicator (60, 60A). [15] Method according to claim 12, wherein a position indicator clip of the position indicator (60, 60A) engages in a disconnect switch surface that points away from a base (84) of the position indicator (60, 60A) when the disconnect switch (56) is in the set position, wherein the clip makes contact with a disconnect switch surface that points towards the base (84) when the disconnect switch (56) is in a removed position. [16] Method according to claim 15, comprising pivoting the position indicator (60, 60A) to engage with the surface facing away from the base (84) and to make contact with the surface facing the base (84).

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