Electrically powered vehicle with a replaceable traction battery

Abstract

An electrically powered vehicle (1) with a replaceable traction battery (2) which is housed in a mounting space (3) of a vehicle body open towards the bottom of the vehicle, which is bounded by side walls (4a, 4b) and at the top by a vehicle floor wall (5), and with a battery connector unit (6) consisting of a vehicle-side connector element (7) and a battery-side sleeve element (8) which can be plugged into one another for electrical contact, characterized in that the vehicle-side connector element (7) of the battery connector unit (6) is pivotably arranged on a side wall (4a) of the mounting space (3) by means of a joint (9), and that the sleeve element (8), which is fixedly attached to the traction battery (2) on the battery side, is a receiving compartment open in the direction of contact pivoting of two high-voltage contact pins (28, 29) with contact elements each connected to a positive terminal and a negative terminal of the traction battery (2). (30,31) is formed, and that the contact elements in the sleeve element (8) are spring-loaded HV contact plates (30, 31) which are displaced under spring preload in the closed position of the adjacent contact pin ends.

Description

[0001] The invention relates to an electrically powered vehicle with a replaceable traction battery according to the preamble of claim 1 and a method for mounting a traction battery in an electrically powered vehicle according to claim 6.

[0002] In a well-known, exemplary electrically powered vehicle, a replaceable traction battery is housed in a mounting compartment open at the bottom of the vehicle body. The traction battery is designed as a cuboid battery block and is inserted from below into the mounting compartment, which is designed with a slight oversize and is bounded by side walls and, at the top, by a floor wall of the vehicle.

[0003] The traction battery is a high-voltage battery (HV battery) that must be electrically connected to the high-voltage network (HV network). A battery connector unit is known for this purpose, consisting of a vehicle-side connector element and a battery-side sleeve element, which can be plugged into each other for electrical contact. In this vehicle, the electrical HV contact is made vertically along the vehicle's Z-axis when the traction battery is inserted into the mounting space. The battery-side connector is vertically oriented and engages with the corresponding vehicle-side mating connector element in a coupling process. Alternatively, the electrical HV contact can also be made horizontally along the vehicle's longitudinal axis.

[0004] This well-known vertically oriented contacting in a single operation, together with the insertion and fixing of the traction battery, can lead to the following disadvantages: Due to the vertically oriented contacts, dirt and moisture can enter the battery connector assembly during battery replacement, negatively impacting the high-voltage contact. Since inserting the traction battery into the mounting space is done in a single coupling process with the connection, and traction batteries are typically heavy and therefore difficult to transport and reposition, handling during battery replacement can be complex. In particular, the connector parts of the battery connector assembly must be precisely aligned when inserting the traction battery into the mounting space. This alignment cannot be guaranteed with improper handling, potentially leading to damage to parts of the connector assembly and even a complete failure of the connection.

[0005] Furthermore, an electrically powered vehicle with a battery connector unit consisting of a plug element and a sleeve element is known (DE 10 2007 028 862 A1), wherein the plug element is fixed to the vehicle and the sleeve element is also arranged on the vehicle and is movable relative to it. The sleeve element can be connected to the vehicle's traction battery with a high-voltage cable. A locking mechanism ensures that contact by plugging the connector unit together is only possible when a locking lever for mechanically securing a battery block in a receiving compartment has been moved from a release position to a locked position.

[0006] Furthermore, an assembly aid for reducing joining and separating forces when contacting a battery connector system for a traction battery of a mobile working machine is known (DE 10 2014 101 469 A9), wherein the contacting is carried out by means of a hand lever and an attached drive lever.

[0007] A method and a system for battery replacement are disclosed in US patent 2018 / 0 118 044 A1. US patent 2015 / 0 129 337 A1 discloses a generic device and a generic method for replacing batteries in battery-powered vehicles. DE patent 10 2018 200 891 A1 discloses a bicycle battery unit and a mounting structure for a bicycle battery unit. EP patent 2 230 164 A1 discloses a bicycle frame for receiving a battery unit and an associated battery unit.

[0008] The object of the invention is to provide an electrically powered vehicle in which changing the traction battery is simplified compared to the prior art.

[0009] The problem is solved by the features of claim 1 or 6. Preferred embodiments of the invention are disclosed in the dependent claims.

[0010] According to claim 1, the vehicle-side connector element of the battery connector unit is pivotably arranged on a side wall of the mounting space by means of a joint. With this inventive design of the battery connector unit and its position on a side wall of the mounting space, the steps of electrical contacting and inserting the traction battery into its mounting space and securing it there can be advantageously carried out largely separately during a battery change, which can facilitate handling and make contacting more reliable. The vehicle-side pivotable arrangement of the connector element offers two possibilities: contacting can be carried out before inserting the traction battery into the mounting space, or contacting can be carried out after inserting and securing the traction battery in the mounting space, as will be explained below with reference to the claimed embodiments.

[0011] In a comparative embodiment not covered by the invention, the vehicle-side, pivotable connector element is arranged as an angled connector element that can be tilted downwards about a horizontal axis at the lower edge of a side wall, preferably a transverse side wall. The battery-side sleeve element is fixedly and immovably arranged at a lower edge of the traction battery and is associated with the position of the angled connector element.

[0012] For coupling, the angled connector element is tilted downwards at an angle of approximately 45°, and the traction battery is brought into contact at a corresponding angle. After contact is established, the traction battery can then be inserted and secured into the mounting space by pivoting the angled connector element back into place. The traction battery can be removed in reverse order.

[0013] This makes the battery replacement process simpler and more manageable, and in particular reduces the risk of insufficient contact due to dirt and moisture.

[0014] In a more detailed embodiment of the comparative form not covered by the invention, the pivotable, vehicle-side connector element has two high-voltage contact pins (HV contact pins) in a connector element housing open in the insertion direction, each connected to flexible high-voltage cables (HV cables) of the vehicle's HV network. Furthermore, the vehicle-side connector element has at least one, preferably two, alignment and positioning pins pointing in the insertion direction within the connector element housing. A battery-side, fixed sleeve element has two socket-shaped high-voltage contact sleeves (HV contact sleeves) in a sleeve element housing open in the insertion direction, each connected to a positive and a negative terminal of the traction battery via a high-voltage cable (HV cable). Additionally, the sleeve element has one, preferably two, guide channels within the sleeve element housing, each associated with the alignment and positioning pins.The housing parts are dimensioned so that, in the contact position, the sleeve element housing overlaps the plug element housing.

[0015] In an exemplary embodiment, the vehicle-side, pivotable connector element is rigidly connected to a side wall, preferably a transverse side wall of the mounting space, via a base part. Two high-voltage contact pins (HV contact pins) are pivotably arranged on the base part by means of a joint with a pivot axis. The arrangement is such that the HV contact pins can pivot out of the mounting space in an open position, corresponding to a separate contact, and pivot into the mounting space in a closed position, corresponding to a contact established. According to the invention, a connector mating element, in the form of a sleeve element fixedly attached to the traction battery on the battery side, is designed as an open receiving compartment, which is open to allow the HV contact pins to pivot in their direction of rotation.The sleeve element as a receiving compartment also contains contact elements connected to a positive and a negative pole of the traction battery, which are preferably arranged opposite and associated with the pivotable HV contact pins in the position of the mounted traction battery.

[0016] In this embodiment, during battery replacement, the traction battery is first inserted and secured in the mounting space without initial contact, with the high-voltage (HV) contact pins in the open position. Subsequently, in a second step, electrical contact can be established independently of the mechanical mounting of the traction battery by pivoting the HV contact pins into the closed position, thus aligning them with the mating contact elements within the sleeve element. This pivoting action can be performed, for example, using a tool attachment at the joint and / or a hand lever, or optionally, by a motor. The traction battery can be removed in reverse order.

[0017] According to the invention, the contact elements in the sleeve element are resiliently mounted high-strength (HV) contact plates which, in the closed position of the adjacent contact pins, are resiliently pre-tensioned and displaced opposite the position of the contact pins. Furthermore, rigidly fixed HV contact plates can be assigned to each of the resiliently mounted, movable HV contact plates in the sleeve element, with the respective associated contact pins engaging between the resiliently mounted HV contact plates and the rigid contact plates in their contact position. In addition, the contact pins of the HV contact pins, intended for contact against contact elements, particularly HV contact plates, can be widened to increase the contact areas, in particular as contact ridges aligned parallel to the pivot axis or aligned in the pivot direction.

[0018] The above measures serve in particular to ensure reliable contact and to advantageously reduce contact resistance. Exemplary embodiments of the invention are explained with reference to a drawing.

[0019] They show: Fig. Figures 1a to 1c schematically depict a battery replacement process in a side view, with a first embodiment of a battery connector unit. Fig. 2 a vehicle-side connector element as an angled connector in two swivel positions, Fig. 3 an enlarged view of the angled plug according to Fig. 2 in a perspective view, Fig. 4 A schematic top view of a battery connector unit before contacting, Fig. 5 a schematic view corresponding to an assembly state after Fig. 1c with a second embodiment of a battery connector unit, Fig. 6 a cross-section through a sleeve element with HV contact plates, Fig. 7 a schematic side view of HV contact pins in two pivot positions, and Fig. 8 a perspective view of a sleeve element accordingly Fig. 6 and of HV contact pins accordingly Fig. 7 before contacting anyone.

[0020] In the Fig. Figures 1a to 1c schematically depict the floor area of ​​an electrically powered vehicle 1 in a side view, as well as a traction battery 2, which, in its installed state, is housed in a mounting space 3 adapted to the dimensions of the vehicle. The mounting space 3 is open at the bottom of the vehicle and bounded by side walls, of which the transverse side walls 4a and 4b are visible, and at the top by a vehicle floor wall 5.

[0021] For contacting the traction battery 2 with the (not further shown) HV network of the vehicle, a first embodiment of a battery connector unit 6 is provided, which consists of a vehicle-side connector element 7 and a battery-side sleeve element 8 associated with it.

[0022] The vehicle-side connector element 7 is arranged at the lower edge of the transverse side wall 4a and is designed to pivot about a horizontal pivot axis of a joint 9. As in Fig. As shown in Figure 2, the swivel range is designed (double arrow 10) such that the connector element 7 can be tilted from a horizontal position into a plug-in position directed downwards by 45°. The battery-side connector counterpart element, as a sleeve element 8, is fixed and immovable at a lower edge and, in the mounted position of the traction battery, is arranged opposite the connector element 7.

[0023] When changing the battery, according to Fig. 1a a traction battery 2 is brought from below to the vehicle 1 at an angle of inclination of 45° with its sleeve element 8 into the area of ​​the plug element 7, wherein the plug element 7 protrudes from the receiving space 3 at an angle of 45° downwards in the manner of an angled plug element.

[0024] In this inclined position, contact is made by placing the traction battery 2 with the sleeve element 8 onto the plug element 7, as shown in Fig. 1b is shown.

[0025] The traction battery 2 is then inserted into the receiving chamber 3 by pivoting it in and fixed there, while at the same time the connector element 7 is pivoted into its horizontal position as an angled connector element, as shown in Fig. 1c is shown. The traction battery can be removed in reverse order.

[0026] In Fig. Figure 2 schematically shows the plug element 7 as an angled plug element, enlarged, and is subsequently described in conjunction with the perspective view. Fig. 3 and with the top view to Fig. 4 explained. The vehicle-side connector element 7 has two high-voltage contact pins, designated HV contact pins 11 and 12, each connected to flexible high-voltage cables, designated HV cables 13 and 14, of the vehicle-side HV network. The connection can be formed, for example, as a soldered, welded, or crimped joint, as is known per se. The HV contact pins 11 and 12 and their connection to the flexible HV cables 13 and 14 are housed in a connector element housing 15 that is open in the direction of insertion. Fig. Figure 3 also shows, schematically and with dashed lines, the connector element housing 15 in the position inclined downwards by 45° about the joint axis of the joint 9. In the top view according to Fig. In a further development, two spaced-apart alignment and positioning pins 16a, 16b, aligned in the insertion direction, are included in the connector element housing 15 (shown here without the top wall). The alignment and positioning pins 16a, 16b protrude from the connector element housing 15 in the insertion direction to ensure the targeted alignment of the connector element 7 and the sleeve element 8, as is also shown in Fig. 2 is indicated. The schematically depicted screw connections 17a and 17b are intended to illustrate that the plug element 7 can be tilted downwards, but is otherwise fixedly connected to the vehicle side.

[0027] According to the top view Fig. Figure 4 shows that the sleeve element 8, which is fixedly attached to the traction battery 2 on the battery side, has two socket-shaped high-voltage contact sleeves (HV contact sleeves 18, 19) in a sleeve element housing 20 that is open in the plug-in direction. Each of these sleeves is connected to a positive terminal 23 and a negative terminal 24 of the traction battery 2 by a high-voltage cable (HV cable 21, 22). Two guide channels 25a, 25b are also shown as dashed lines in the sleeve element housing 20. These guide channels correspond to the alignment and positioning pins 16a, 16b with their respective directions. In the contact position, the sleeve element housing 20 overlaps the plug element housing 15.

[0028] In Fig. 5 is like in the Fig. Figures 1a to 1c schematically show a side view of a floor area of ​​a battery-powered vehicle 1, depicted with a traction battery 2 and an associated mounting space 3, but with a second embodiment of a battery connector unit 6, which is shown in detail in the Fig. 6, Fig. 7 and Fig. Section 8 is explained.

[0029] In the arrangement according to Fig. In step 5, the traction battery 2 is already inserted into the assembly space 3 and mechanically secured there. Furthermore, the electrical connection with the battery connector unit 6 has already been made.

[0030] For contacting purposes, the modified swiveling plug element 7 is arranged in the lower area of ​​the transverse side wall 4b on the vehicle side.

[0031] As from the Fig. 7 and Fig. As can be seen in Figure 8, the connector element 7 has a base part 26 as a vehicle-mounted bracket, on which two spaced-apart high-voltage contact pins, designated as HV contact pins 28 and 29, project via a pivot joint 27 with a horizontally and transversely oriented pivot axis. The contact pins 28 and 29 can be, as shown in Fig. 7a and Fig. 8 shown, protrude upwards and thus out of the area of ​​the assembly space 3, or are pivoted by approximately 90° into the area of ​​the assembly space 3, as shown in Fig. 5 and Fig. 7b is shown.

[0032] The sleeve element 8 is fixedly attached to the traction battery 2 as a receiving compartment open at the top in the pivoting direction of the high-voltage contact pins 28, 29 at a position corresponding to the plug element 7. The sleeve element 8 contains spring-mounted high-voltage contact plates as HV contact plates 30, 31, which are each connected to a positive and negative terminal of the traction battery 9 via (not shown) HV cables. As can be seen from the cross-sectional view according to Fig. As can be seen in Figure 6, rigidly arranged HV contact plates 32 are mounted in the sleeve element 8 opposite the spring-mounted HV contact plates 30, 31, with the ends of the HV contact pins 28, 29 engaging in the contact position between the contact plates and being spring-loaded. To maximize the contact area, the contact pin ends are enlarged with contact ribs 33, 34, which are parallel to the pivot axis (according to Figure 6). Fig. 8) or in the direction of rotation (accordingly Fig. 5 and Fig. 7) may be aligned. Reference symbol list 1 vehicle 2 traction batteries 3 Assembly room 4a, 4b transverse side walls 5 Vehicle floor wall 6 Battery connector unit 7 Plug element 8 sleeve element 9 joint 10 Double Arrow 11 HV contact pin 12 HV contact pins 13 HV cables 14 HV cables 15 connector element housings 16a, 16b Alignment and positioning pins 17a, 17b Screw connection 18 HV contact sleeve 19 HV contact sleeve 20 sleeve element housings 21 HV cables 22 HV cables 23 Positive terminal 24 Negative terminal 25a, 25b Guide channel 26 Basic part 27 Swivel joint 28 HV contact pins 29 HV contact pin 30 HV contact plates 31 HV contact plates 32 HV contact plates 33 Contact bridge 34 Contact bridge 35 Contact bridge

Claims

[1] Electrically powered vehicle (1) with a replaceable traction battery (2) which is accommodated in a mounting space (3) of a vehicle body open to the bottom of the vehicle, which is bounded by side walls (4a, 4b) and at the top by a vehicle floor wall (5), and with a battery connector unit (6) consisting of a vehicle-side connector element (7) and a battery-side sleeve element (8) which can be plugged into each other for electrical contact, characterized by, that the vehicle-side connector element (7) of the battery connector unit (6) is pivotably arranged on a side wall (4a) of the mounting space (3) by means of a joint (9), and that the sleeve element (8) fixedly attached to the traction battery (2) on the battery side is designed as a receiving compartment open in the contact pivoting direction of two high-voltage contact pins (28, 29) with contact counterpart elements (30, 31) connected to a positive terminal and a negative terminal of the traction battery (2), and that the contact counterpart elements in the sleeve element (8) are spring-loaded HV contact plates (30, 31) which are displaced under spring preload in the closed position of the adjacent contact pin ends. [2] Electrically powered vehicle according to claim 1, characterized by, that the vehicle-side, pivotable connector element (7) is fixedly connected to a base part (26) with a side wall, namely a side transverse wall (4b) of the mounting space (3), and / or that the high-voltage contact pins (28, 29) are pivotably arranged on the base part (26) by means of a joint with a pivot axis (27), such that they are pivotable out of the area of ​​the mounting space (3) in an open position or pre-assembly position corresponding to separate contacting and pivotable into the area of ​​the mounting space (3) in a closed position or final assembly position corresponding to established contacting, and / or that the sleeve element (8) is attached at a location associated with the position of the pivotable HV contact pins (28, 29) in the position of the mounted traction battery (2), wherein the traction battery (2) can be inserted and fixed in the mounting space (3) without contacting when the HV contact pins are in an open position. HV contact pins (28,29) and subsequently contact is established by pivoting the HV contact pins (28, 29) into the closed position and thus into the sleeve element (8) with a contact against the counter-contact elements (30, 31). [3] Electrically powered vehicle according to claim 1 or 2, characterized by , that in the sleeve element (8) rigidly fixed HV contact plates (32) are assigned opposite the spring-mounted, movable HV contact plates (30, 31) and the respective assigned contact pin ends engage in the contact position between the spring-mounted HV contact plates (30, 31) and the rigid contact plates (32). [4] Electrically powered vehicle according to any of the preceding claims, characterized by , that the contact pin ends of the HV contact pins (28, 29) intended for contact with HV contact plates (30, 31, 32) are designed to be wider in order to increase the contact area. [5] Electrically powered vehicle according to claim 4, characterized by , that the contact-makers are trained as contact bridges (33, 34). [6] Method for mounting a traction battery in an electrically powered vehicle according to one of the preceding claims.

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