High-voltage connector

Abstract

High-voltage connector (10) for commercial vehicles, comprising a cable part (13) for receiving a high-voltage cable (12) and a contact part (15) for receiving a contact pin (14), wherein the cable part (15) has a cable part housing (16) and a selector device (20) rotatably mounted on the cable part housing (16) about a selector rotary axis (26) in order to press a fixing clip (34) arranged in the cable part housing (16) against an insertion element (38) of the contact pin (14) extending into the cable part housing (16) by rotating the selector device (20), wherein the insertion element (38) is received in a contact socket (40) formed in the cable part housing (16) with a conical contact surface.

Description

TECHNICAL AREA

[0001] The present invention relates to the field of commercial vehicles, in particular to high-voltage connectors for the electrical power supply of an at least partially electrified commercial vehicle. TECHNICAL BACKGROUND

[0002] Modern commercial vehicles often transmit high currents to power the vehicle itself or attached work equipment (such as a turntable ladder). High-voltage connectors are used for this purpose, typically comprising a cable section for a high-voltage cable and a contact section for a contact pin. The high-voltage cable is connected, for example, to a battery, while the contact pin is connected to a DC / AC inverter. To ensure current transmission, it is essential that the electrical contact between the high-voltage cable and the contact pin is reliable. Various high-voltage connectors are known in the prior art. However, with these known connectors, the electrical contact is only conditionally reliable. This is due to an inadequate mechanical connection between the high-voltage cable and the contact pin.

[0003] The invention is therefore based on the objective of providing a high-voltage connector that ensures a secure electrical contact between the high-voltage cable and the contact pin.

[0004] This task is solved by a high-voltage cable and a commercial vehicle in accordance with the independent claims.

[0005] The high-voltage connector is used in commercial vehicles, particularly partially electrified commercial vehicles, to conduct high currents. The high-voltage cable is a two-part assembly comprising a cable section for holding the high-voltage cable and a contact section for holding a contact pin. The cable section is typically connected to a battery, while the contact pin is typically connected to a DC / AC inverter. The cable section includes a housing and a selector mechanism rotatably mounted on the housing about a selector axis. Rotating the selector mechanism presses a steel clamp located within the housing against an insertion element of the contact pin that extends into the housing.

[0006] The selector assembly preferably comprises a selector lever mounted outside the cable housing and a selector disc mounted inside the cable housing. The selector lever and the selector disc are preferably rotatable coaxially about the selector's axis of rotation. The selector disc can be rotated by actuating the selector lever. The selector assembly preferably has a connecting rod that is rotatably fixed to an end of the selector disc opposite the axis of rotation. In this way, rotating the selector lever causes at least a partial longitudinal movement of the connecting rod.

[0007] The plug-in element is received in a contact socket with a conical contact surface formed in the cable housing. Preferably, the plug-in element is positively engaged in the contact socket. For this purpose, the plug-in element also has a conical contact profile, which can be brought into appropriate engagement with the conical contact surface.

[0008] The contact socket preferably has two platforms for supporting a retaining clip. The contact socket is formed between the platforms. A retaining clip is also preferably arranged in the cable housing. The retaining clip has a clamp spring and two side springs arranged laterally to the clamp spring. When the retaining clip is inserted in the cable housing, the side springs press against the platforms of the contact socket.

[0009] The locking clip has a projection on one side facing the insertion element. This projection can engage in a recess formed on the same side of the insertion element. In this way, an electrical contact can be established between the locking clip and the contact pin. In a first state of the locking clip, when the selector is in a first rotational position, the projection is spaced apart from the recess of the insertion element due to the spring force of the side springs. In a second state of the locking clip, when the selector is in a second rotational position, the projection engages in the recess against the spring force of the side springs.

[0010] The locking clamp can be moved between the first and second positions using the selector mechanism. For this purpose, a connecting element is held on its underside by the clamp spring of the locking clamp and laterally by the connecting rod above the locking clamp. Preferably, the connecting element is bounded on its upper side by a guide surface. In this way, the connecting element is held in a frictional position within a space defined by the guide surface, the connecting rod, and the locking clamp or the clamp spring. The connecting element is preferably frictionally connected to the connecting rod so that, by actuating the selector lever, the connecting element can be moved by means of the movement of the connecting rod.

[0011] The connecting element is preferably wedge-shaped, and more preferably double-wedge-shaped. In an open position of the selector lever, where the raised section of the locking clip is extended from the recess of the contact pin's insertion element, the double-wedge-shaped connecting element engages an inclined surface of the guide surface with its upper wedge face. Simultaneously, the double-wedge-shaped connecting element engages an inclined surface of the clamp spring with its lower wedge face. In a closed position of the selector lever, where the raised section of the locking clip engages in the recess of the contact pin's insertion element, the connecting element is displaced further in the direction away from the connecting rod compared to the open position of the selector lever.In this state, the connecting element with its upper horizontal surface contacts a horizontal surface of the guide slat, while the connecting element with its lower horizontal surface contacts a tip point of the clamp spring.

[0012] The connecting element is therefore held securely between the guide surface and the locking clip. In this way, when the locking clip is closed, the raised section can be inserted into the recess of the insertion element and held there securely, preferably also positively. The positive or positive connection between the raised section of the locking clip and the insertion element of the contact pin serves to reinforce the mechanical connection between the insertion element and the contact socket. This effectively prevents any contact gaps between the insertion element and the contact socket that might be caused by vibrations or the thermal properties of the materials used in the high-voltage connector. In this way, reliable electrical contact between the high-voltage cable and the contact pin is ensured.

[0013] Advantageous designs and further developments are specified in the subclaims.

[0014] Exemplary embodiments are now described by way of example and with reference to the accompanying drawings. These show: Fig. 1 a schematic representation of a high-voltage connector according to an embodiment in a perspective view, wherein the high-voltage connector comprises a cable part for receiving a high-voltage cable and a contact part with a contact pin; Fig. 2 a schematic representation of the high-voltage connector in a sectional view, in which the cable part and the contact part are separated from each other; Fig. 3 a schematic representation of the high-voltage connector in a perspective view, in which the cable part and the contact part are separated from each other; Fig. 4 a schematic representation of the high-voltage connector in a sectional view in which the cable part and the contact part are connected to each other, the contact pin being in a cable part housing of the cable part in an unlocked state; Fig. 5 a schematic representation of the high-voltage connector in a perspective view in which the cable part and the contact part are connected to each other, the contact pin being in a cable part housing of the cable part in the unlocked state; Fig. 6 A schematic representation of the high-voltage connector in a sectional view along a section line AA in the Fig. 5 shown illustration; Fig. 7 a schematic representation of the fixing clamp in a perspective view; Fig. 8 a schematic representation of the high-voltage connector in a sectional view in which the cable part and the contact part are connected to each other, the contact pin being in a cable part housing of the cable part in a locked state; Fig. 9 A schematic representation of the high-voltage connector in a sectional view along a section line BB in the Fig. 8 shown in the illustration; and Fig. 10 A schematic representation of the high-voltage connector in a perspective view in which the cable part and the contact part are connected together, with the contact pin being in a cable part housing of the cable part in the locked state.

[0015] In the figures, identical reference symbols refer to identical or functionally similar reference parts. The relevant reference parts are identified in each figure.

[0016] Fig. Figure 1 shows a schematic perspective view of a high-voltage connector 10. The high-voltage connector 10 comprises a cable section 13 and a contact section 15. The cable section 13 is designed to accommodate a high-voltage cable 12 and has a cable section housing 16 for this purpose. The high-voltage cable 12 is connected, for example, to a battery. The contact section 15 is designed to connect to a load, such as an electric motor, and has a contact section housing 18 for receiving a contact pin 14. For example, the contact section 15 is connected to a DC / AC inverter connected between the battery and the electric motor. The cable section housing 16 and the contact section housing 18 form a two-part housing for the high-voltage connector 10. The housing can be made of metal, plastic, or another material with comparable strength and weight.

[0017] Fig. Figure 2 shows the high-voltage connector 10 in a side sectional view. The internal structure of the high-voltage connector 10 is visible here. The cable section 13 includes a selector 20, by means of which the contact pin 14 can be brought into a locked position. The selector 20 comprises a selector lever 22, which is rotatably mounted outside the cable section housing 16 about a selector axis 26. The selector 20 also includes a selector disc 24, which is likewise rotatable about the selector axis 26. The selector disc 24 is rotatably connected at one end away from the selector axis 26 to a connecting rod 28 about an axis of rotation 30. At the other end away from the axis of rotation 30, a movement element 32 is movably arranged in contact with the connecting rod 28.

[0018] In the cable housing 16, an interior space is formed at the end facing the contact part 15 for placing a retaining clip 34. The retaining clip 34 has a clamping spring 36 and two side springs 48. The structure of the retaining clip 34 is shown in Fig. 7 shown in more detail. Fig. 3 is the high-voltage connector 10 from Fig. 2 shown in a perspective view.

[0019] In Fig. 2 and Fig. Figure 3 shows the high-voltage connector 10 in a state where the cable part 13 and the contact part 15 are separated. Thus, the insertion element 38 is not received by a contact socket 40 formed in the cable part housing 16. In this state, an insertion element 38 formed on the contact pin 14, which passes through and over the contact part housing 18, is separated from the cable part 13. The selector lever 22 is in an open position, in which the selector lever 22 is rotated maximally upwards (in the illustration, maximally counterclockwise). In this state, the connecting rod 28, and thus also the movement element 32, is moved maximally to the left. The movement element 32 has a double-wedge-shaped head, the two opposing wedge surfaces of which act on one side on an inclined surface 62 of the guide surface 44 and on the other side on the clamping spring 36 from above.The clamping spring 36 is minimally compressed in this state and is supported by the side springs 48 against two laterally arranged platforms 46 (or contact surfaces), between which the conical contact surface of the contact bushing 40 is formed. The fixing clamp 34 has a projection 60 on its underside, which in the state shown is not received by a recess 58 formed in the insertion element 58.

[0020] Fig. Figure 4 schematically shows the high-voltage connector 10 in a state where the cable part 13 and the contact part 15 are engaged. The insertion element 38 is received by the contact socket 40 in the cable part housing 18. The selector lever 22 is located in the Fig. 2-3 already shown opening position, so that the fixing clamp 34 remains in an unlocked state and does not engage in the insertion element 38. Fig. 5 shows the high-voltage connector 10 from Fig. 4 in a perspective view. In Fig. 6 is the high-voltage connector 10 from Fig. 4-5 in a sectional view along the in Fig. 4 indicated section plane AA shown. In Fig. Figure 6 shows the conical contact surface of the contact socket 40. It is also evident that the insertion element 38 has a similarly conical contact profile, such that the insertion element 38 engages with the contact socket 40 in a form-fitting manner.

[0021] Fig. Figure 7 shows the fixing clamp 34 in a perspective view. The fixing clamp 34 comprises a clamp spring 36 and two side springs 48, which are attached laterally to the clamp spring 36. The clamp spring 36 has a spring plate 37, which is formed integrally with a base body 39. When a compressive force is exerted on the spring plate 37 from above, the spring plate 37 can be bent against the base body 39. In this way, the fixing clamp 34 is tensioned.

[0022] If, as in Fig. As indicated by arrow 52, ​​when the selector lever 22 is rotated clockwise in the illustration, this sets the connecting rod 28 into a longitudinal movement via the selector disc 24 (arrow 54). This displaces the moving element 32 against the restoring force of the clamping spring 36 in the direction away from the connecting rod 28. Due to the compression of the clamping spring 36, a gap opens between the clamping spring 36 and the guide surface 44, into which the moving element 32 is pushed. Simultaneously, the locking clip 34 is pressed downwards due to the compression of the clamping spring 36 (arrow 56). Thus, the projection 60 engages with the recess 58 of the insertion element 38 and is fully received by the recess 58.

[0023] This results in a state in which the contact pin 14 is locked due to the positive connection between the protrusion 60 and the recess 58. Fig. Figure 8 schematically shows the high-voltage connector 10 in this state. It can be seen that the selector lever 22 is rotated to its maximum clockwise position. Thus, the connecting rod 28, and consequently also the moving element 32, is shifted to its maximum rightward position. The moving element 32 is held in a force-fit position between the guide surface 44 and the fixing clamp 34. In this position, the horizontally oriented upper surface of the moving element 32 contacts a horizontal surface 50 of the guide surface 44. Due to the horizontal displacement, the upper wedge surface of the wedge-shaped head of the moving element 32 is exposed.

[0024] Fig. Figure 9 shows a sectional view of the in Fig. The high-voltage connector 10 shown in Figure 8 is shown along a section plane BB. It can be seen that the projection 60 of the fixing clip 34 is now positively engaged by the recess 58 of the insertion element 38. Fig. 10 shows the one in Fig. 8 high-voltage connectors 10 shown in a perspective view.

[0025] The locking mechanism of the contact pin 14 in the cable part housing 16 reinforces the mechanical connection between the cable part 13 and the contact part 15 of the high-voltage connector 10. This ensures a reliable electrical contact between the high-voltage cable 12 (or rather its current-conducting cable core, which is enclosed by insulation) and the contact pin 14, even under vibrations and thermal deformations of the materials used in the high-voltage connector 10. Reference sign 10 high-voltage connectors 12 high-voltage cables 13 Cable section 14 Contact pin 15 Contact part 16 cable housings 18 contact part housings 20 dialing device 22 Selector lever 24 dial 26 Selector rotary axis 28 Connecting rod 30 Rotary axis 32 Movement element 34 fixing clamps 36 clamp spring 37 Spring plate 38 Insert element 39 Basic bodies 40 contact socket 42 Arrow 44 guide surface 46 Stage 48 side springs 50 Horizontal area 52, 54, 56 Arrow 58 Exclusion 60 Survey 62 inclined surface

Claims

[1] High-voltage connector (10) for commercial vehicles, comprising a cable part (13) for receiving a high-voltage cable (12) and a contact part (15) for receiving a contact pin (14), wherein the cable part (15) has a cable part housing (16) and a selector device (20) rotatably mounted on the cable part housing (16) about a selector rotary axis (26) in order to press a fixing clip (34) arranged in the cable part housing (16) against an insertion element (38) of the contact pin (14) extending into the cable part housing (16) by rotating the selector device (20), wherein the insertion element (38) is received in a contact socket (40) formed in the cable part housing (16) with a conical contact surface. [2] High-voltage connector (10) according to claim 1, wherein the insertion element (38) has a conical contact profile in order to be positively received in the contact socket (40). [3] High-voltage connector (10) according to claim 1 or 2, wherein the contact socket (40) has two stages (46) for supporting the fixing clamp (34), wherein the conical contact surface of the contact socket (40) is formed between the stages (46). [4] High-voltage connector (10) according to claim 3, wherein the fixing clamp (34) has a clamp spring (36) and two side springs (48) arranged laterally to the clamp spring (36), wherein the side springs (48) press against the stages (46) of the contact socket (40). [5] High-voltage connector (10) according to claim 4, wherein the fixing clip (34) has a protrusion (60) on a side facing the insertion element (38) which can engage in a recess (58) formed on a side of the insertion element (38) facing the fixing clip (34) in order to lock the contact pin (14) in the cable part housing (16). [6] High-voltage connector (10) according to claim 5, wherein the projection (60) in a first state of the fixing clamp (34), in which the selector device (20) is in a first rotational position, is spaced apart from the recess of the insertion element (38) due to a spring force of the side springs (48), wherein the projection (60) in a second state of the fixing clamp (34), in which the selector device (20) is in a second rotational position, engages in the recess (58) against the spring force of the side springs (48). [7] High-voltage connector (10) according to one of claims 4 to 6, wherein the selector device (20) has a selector lever (22) mounted outside the cable part housing (16) and a selector disc (24) mounted inside the cable part housing (16), wherein the selector lever (22) and the selector disc (24) are rotatable coaxially about the selector rotation axis (26). [8] High-voltage connector (10) according to claim 7, wherein the selector device (20) has a connecting rod (28) which is rotatably fixed to an end of the selector disc (24) facing away from the selector axis of rotation (26), such that a rotation of the selector lever (22) causes at least a partial longitudinal movement of the connecting rod (28). [9] High-voltage connector (10) according to claim 8, wherein a connecting element (32) is held on the underside by the clamp spring (36) of the fixing clamp (34) and laterally by the connecting rod (28) above the fixing clamp (34). [10] High-voltage connector (10) according to claim 9, wherein the connecting element (32) is limited on its upper side by a guide surface (44), so that the connecting element (32) is held in a force-locking position of the selector lever (22), in which the projection (60) of the fixing clip (34) engages in the recess (58) of the insertion element (38) of the contact pin (14), between the guide surface (44) and an upper side of the fixing clip (34). [11] High-voltage connector (10) according to claim 10, wherein the connecting element (32) is wedge-shaped, preferably double wedge-shaped. [12] Commercial vehicle, with a high-voltage connector (10) according to one of the preceding claims.

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