Device for monitoring an electrical enclosure, in particular a battery enclosure

Abstract

The invention relates to a device (1) for monitoring an electrical housing (2) for liquid ingress, comprising a sensor (4) for detecting the liquid ingress. The device includes a multi-part flexible sensor housing (6) in which the sensor (4) is arranged on a sensor housing base (6.1.1). The flexible sensor housing (6) is configured to hold the sensor (4) at a defined axial distance (100) from the housing base (2.1) of the electrical housing (2) to be monitored. The sensor housing (6) comprises at least two sensor housing parts (6.1, 6.2) which are held in a self-adjusting axial compensation distance (102) relative to each other by means of at least one spring element (10) arranged between these two sensor housing parts (6.1, 6.2).

Description

[0001] The invention relates to a device for monitoring an electrical housing, in particular a battery housing, for liquid ingress with a sensor for detecting the liquid ingress.

[0002] In the electrical enclosures of electrical devices or systems, such as chargers, power electronics, batteries (especially high-voltage batteries), accumulators, supercapacitors, high-voltage components of drive circuits, or the like, the accumulation of liquids such as condensation, dirty water, aqueous solutions, electrolyte fluid, or the like can lead to critical situations due to unwanted leakage currents and / or electrical short circuits. Various solutions are known for detecting water entering the electrical enclosure. These detect and indicate a change, for example, in current flow, conductivity, resistance, or escaping gas, upon contact with water.

[0003] EP 2 365 575 A1 discloses a sensor based on a porous absorption layer for absorbing liquid, wherein the sensor selectively detects whether it is in contact with water, with an electrolyte, and / or not with a liquid at all. DE 10 2020 001 393 A1 discloses arranging a powder or granulate in the base region of the battery housing and providing a sensor sensitive to a released gas as the sensor. DE 10 2016 212 986 A1 discloses a liquid measuring device with a measuring head. EP 2 695 228 A2 discloses a device and a method for leak testing of an electrochemical energy storage device.

[0004] DE 10 2019 206 106 A1 discloses a drainage device 14 for an electrical component of a motor vehicle, wherein the drainage device 14 has a closure device 16 for closing an opening 12b, 32a in a housing 12 of the electrical component or in a pipe 32 coupled to the housing 12, and a release device 20 designed to release the opening 12b, 32a in the event that at least one specific liquid is located in at least one specific area 18. The release device 20 is designed to react chemically upon contact with the at least one specific liquid and, through this reaction, to release the opening 12b, 32a by at least partially removing the closure device 16.

[0005] The invention is based on the object of providing an easy-to-install device for monitoring an electrical enclosure for liquid ingress. This object is achieved according to the invention by a device for monitoring an electrical enclosure for liquid ingress according to the features of claim 1.

[0006] Advantageous embodiments of the invention are the subject of the subclaims.

[0007] The device according to the invention for monitoring an electrical housing for liquid ingress with a sensor for detecting the liquid ingress comprises a multi-part, in particular two-part, flexible sensor housing in which the sensor is arranged on a sensor housing base. The spring-loaded sensor housing is configured to hold the sensor at a defined axial distance from a housing base to be monitored. The sensor housing comprises at least two sensor housing parts, which are held in a self-adjusting manner at an axial compensation distance from one another by means of at least one spring element arranged between these two sensor housing parts.

[0008] The invention is based on the idea of ​​providing and using a flexible sensor housing, particularly preferably a two-part, spring-loaded sensor housing, wherein a contact to the sensor (also called measuring system) is arranged on the sensor housing base, in particular a lower sensor housing half or sensor housing part, at a defined distance from the housing base to be monitored of the electrical housing or of an electrical component, in particular of an electrical vehicle component.

[0009] The advantages achieved with the invention consist in particular in the fact that it enables the protection of electrical components or parts, in particular high-voltage components, accumulators, batteries, battery cells or the like, against damage caused by leakage currents and short circuits. In particular, a user can be protected from cross-circuits on touchable surfaces, for example by switching off or deactivating the electrical component if liquid ingress is detected. Furthermore, due to the flexible sensor housing, the invention enables tolerance-compensating installation of the sensor in the electrical housing to be monitored. Furthermore, the invention enables cost-effective and simplified installation of the sensor in a single assembly step in both new and existing electrical housings without manual adjustment processes and without changing the assembly line.Furthermore, the invention enables reliable detection of only damage-relevant fluid quantities and can be used for early warning and / or rapid deactivation or shutdown of electrical components to reduce or prevent failure and / or damage to the electrical component, particularly a cost-intensive battery, a high-voltage component, power electronics, an electric drive, or the like. The electrical housing can then be dried and repaired if necessary. Furthermore, false detections, such as triggering due to individual drops, can be prevented by the defined distance between the sensor and the housing base to be monitored, thus avoiding unnecessary visits to the workshop.

[0010] In a further embodiment, the sensor is protected by the sensor housing against particle ingress and malfunction due to short circuits, in particular when using the high-voltage monitoring functions already present in the battery as a detection principle.

[0011] The sensor can be configured, for example, as an electrical measuring system for detecting an electrical conductivity, a change in a permittivity of a capacitor characteristic due to electrolyte ingress, a change in an electrochemical impedance upon application of an alternating current or, particularly preferably, a current flow upon application of a direct current or the like, in order to detect and determine an ingress of liquid, for example an ingress of water, dirty water, condensate water, electrolyte liquid or the like, based on the detected measured values.

[0012] For example, the distance, in particular a spatial, in particular axial, extension of the sensor (also called sensor element, receiving element or detection element) and / or a spatial, in particular axial, extension of a sensor carrier on the sensor housing base can be selected such that the resulting distance of the sensor to the housing base to be monitored of the electrical housing to be protected or of a component to be protected, such as a vehicle component to be protected, is dimensioned such that only the occurrence of a quantity of liquid relevant for a fault case leads to a triggering, in particular rapid, of the sensor.

[0013] In one possible embodiment, the sensor housing can comprise at least two sensor housing parts that are / are held flexibly and self-adjustingly at an axial compensation distance from one another. The at least two sensor housing parts are held in a self-adjusting manner at the axial compensation distance from one another, in particular one that compensates for tolerances, by means of at least one spring element arranged between these two sensor housing parts. The spring element can, for example, be arranged and supported on the one hand on the sensor housing base of one sensor housing part and on the other hand on the sensor housing base of the other sensor housing part. Multiple spring elements can also be provided. Furthermore, the spring elements can each be arranged and supported at their spring ends on a spring bearing. If there are multiple spring elements, in particular two spring elements, these and the sensor are / are arranged symmetrically to one another.In particular, the sensor can preferably be arranged centered to and / or between the spring elements, wherein the spring elements are arranged symmetrically distributed around the sensor.

[0014] A further embodiment provides that a first sensor housing part is arranged and held in a fixed position on the housing base to be monitored. A base of this first, fixed sensor housing part forms the sensor housing base on which the sensor is arranged. In particular, the sensor is arranged on an inner side of the sensor housing base of this first, fixed sensor housing part.

[0015] Furthermore, a second sensor housing part is provided, which is / is arranged flexibly, in particular axially movable, relative to the first sensor housing part by means of the spring element. This second sensor housing part can be / is designed, for example, as a metallic housing and as a measuring electrode of the sensor. Alternatively, the second sensor housing part can be / is formed by a region of the electrical housing or a component in the electrical housing. The second sensor housing part can also be designed such that no further contacting of the electrical housing and / or a component in the electrical housing, for example, by a vehicle component, is necessary.

[0016] The type, structure, material, and / or arrangement of the sensor housing components depend / depends in particular on the type of sensor used. For example, if the sensor itself is designed as a multi-electrode sensor, e.g., a 2-electrode sensor for measuring conductivity, contact with a liquid, and / or permittivity, no additional contact with a sensor housing component is necessary. Alternatively, the sensor can form a sensor electrode, and one of the sensor housing components and / or a region of the electrical housing and / or a component within the electrical housing can form another sensor electrode of the sensor.

[0017] In one possible embodiment, the two sensor housing parts can be designed as two U-shaped sensor housing shells which are inserted into one another with their open ends to form a hollow space and which are held flexibly and self-adjusting relative to one another by means of the spring element. For example, one of the sensor housing parts can be arranged radially inward and the other sensor housing part radially outward. The sensor housing parts can be arranged flexibly overlapping one another in some areas. In particular, the two sensor housing parts can each be designed as a hollow, in particular annular-cylindrical or angular, sensor housing part that is axially open on one side. One of the sensor housing walls of the sensor housing parts can be designed as an outer wall of the sensor housing, in particular a hollow cylinder.Another of the sensor housing walls can be designed as an inner wall of the sensor housing, in particular a hollow cylindrical one. Both sensor housing parts can each have a sensor housing base, in particular a radial base wall.

[0018] The spring element can be designed as a single preload spring or as a plurality of preload springs. In the sensor housing, the other sensor housing part is axially supported and axially displaceably mounted by means of at least one preload spring on the sensor housing base of one of the sensor housing parts.

[0019] Additionally, depending on the type of sensor, the axially movable second sensor housing part can be adjacent to, or arranged and secured to, a busbar. Alternatively, the second sensor housing part can be formed by a shell-shaped receptacle for the busbar itself, and this busbar can be mounted axially movable relative to the first sensor housing part.

[0020] The spring element is designed in particular as a preload spring and can have a spring force such that it automatically or self-adjustingly holds the two sensor housing parts in the axial compensation distance when mounted in an assembly space between the housing base to be monitored and the busbar opposite this housing base.

[0021] In addition, a distance limiter can be provided to limit the axial compensation distance. The distance limiter can be formed, for example, as at least one recess, in particular an axial groove, in one of the sensor housing walls of one of the sensor housing parts, into which a guide element protruding radially from the other sensor housing wall of another sensor housing part engages.

[0022] Embodiments of the invention are explained in more detail below with reference to drawings.

[0023] Showing: Fig. 1 schematically shows a sectional view of a device for monitoring an electrical housing for liquid ingress with a sensor for detecting the liquid ingress, and Fig. 2 schematically shows in partially transparent perspective view the device for monitoring an electrical housing.

[0024] Corresponding parts are provided with the same reference numerals in all figures.

[0025] Fig. 1 shows a device 1 for monitoring an electrical enclosure 2 (shown in Fig. 2) to a liquid inlet. From the electrical housing 2, Fig. 2 shows a housing base 2.1 on which a sensor 4 is arranged to detect liquid ingress into the electrical housing 2.

[0026] The sensor 4 can be a conventional sensor for detecting a liquid. The sensor 4 can, for example, be configured as an electrical measuring system for detecting electrical conductivity, a change in the permittivity of a capacitor characteristic due to electrolyte ingress, a change in electrochemical impedance upon application of an alternating current, or particularly preferably, a current flow upon application of a direct current, or the like, in order to detect and determine the ingress of liquid, for example, the ingress of water, dirty water, condensate, electrolyte fluid, or the like, into the electrical housing 2 based on the detected measured values.

[0027] The electrical housing 2 is in particular a housing for accommodating electrical components or electrical parts, such as a battery, a high-voltage battery, power electronics, an accumulator, a high-voltage component or the like.

[0028] The sensor 4 comprises a multi-part, in particular two-part, flexible sensor housing 6. The sensor housing 6 comprises in particular a first sensor housing part 6.1 and a second sensor housing part 6.2, which are arranged flexibly relative to one another, for example are arranged so as to be movable relative to one another.

[0029] The sensor 4 is arranged in the sensor housing 6 on a sensor housing base 6.1.1 of the first sensor housing part 6.1. The sensor 4 can be arranged and fastened on a sensor carrier 6.1.2 on the sensor housing base 6.1.1. For example, the sensor 4 can be connected to the sensor housing base 6.1.1, in particular to the sensor carrier 6.1.2, in a form-fitting, force-fitting, and / or material-fitting manner. For example, the sensor 4 and the sensor carrier 6.1.2 can be magnetically connected to one another. Alternatively, the sensor 4 can be glued, screwed, or clipped onto the sensor carrier 6.1.2.

[0030] The sensor housing 6 is preferably configured to hold the sensor 4 at a defined axial distance 100 from a housing base 2.1 of the electrical housing 2 to be monitored.

[0031] For this purpose, the sensor housing 6 is / is connected to the housing base 2.1 to be monitored in a form-fitting, force-fitting, and / or material-fitting manner. For example, the sensor housing 6 is / is connected to the, for example, metallic housing base 2.1 of the electrical housing 2 by means of a magnet 8. Alternatively, the sensor housing 6 can be screwed, clipped, or glued to the housing base 2.1, for example using an adhesive pad. Furthermore, a hole (not shown) can optionally be provided in the sensor housing base 6.1.1 in the area of ​​the sensor 4 for fluid access.

[0032] The axial distance 100 of the sensor 4 to the housing base 2.1 to be monitored, in particular a spatial, in particular axial, extension of the sensor 4 (also called sensor element, receiving element or detection element) and / or a spatial, in particular axial, extension of the sensor carrier 6.1.2 on the sensor housing base 6.1.1 to an upper side of the housing base 2.1 to be monitored, is to be selected such that only the occurrence of a quantity of liquid relevant for a fault case leads to a triggering, in particular rapid, of the sensor 4. In other words: An axial distance 100 of the sensor 4 to the housing base 2.1 to be monitored of the electrical housing 2 to be protected or of a component to be protected, such as a vehicle component to be protected, resulting from the dimensions, in particular the height, of the sensor carrier 6.1.2 and optionally of the sensor 4, is dimensioned in order to detect a relevant ingress of liquid into the electrical housing 2 largely without errors.

[0033] The two sensor housing parts 6.1 and 6.2 can also be held flexibly and self-adjustingly at an axial compensation distance 102 from each other for easy assembly. The at least two sensor housing parts 6.1, 6.2 are held self-adjustingly at the axial compensation distance 102 from each other by means of at least one spring element 10 arranged between these two sensor housing parts 6.1, 6.2, in particular compensating for axial component and / or assembly tolerances.

[0034] The spring element 10 can, for example, be arranged and supported on the one hand on the sensor housing base 6.1.1 of the first sensor housing part 6.1 and on the other hand on an opposite sensor housing base 6.2.1 of the second sensor housing part 6.2. Multiple spring elements 10, in particular two spring elements 10, can also be provided. The spring elements 10 can each be arranged and supported on a spring bearing 10.1 at their respective spring ends. The spring bearings 10.1 can be integrated into the respective sensor housing base 6.1.1, 6.2.1. For example, the spring bearings 10.1 can be designed as support bolts or support pins projecting vertically from the respective sensor housing base 6.1.1, 6.2.1.

[0035] If there are multiple spring elements 10, these and the sensor 4 are arranged symmetrically to one another. In particular, the sensor 4 can preferably be arranged centered relative to and / or between the spring elements 10. Furthermore, the spring elements 10 can be arranged symmetrically distributed around the sensor 4.

[0036] The first sensor housing part 6.1 is arranged and held in a fixed position on the housing base 2.1 to be monitored. The sensor housing base 6.1.1 of this first, fixed sensor housing part 6.1 forms the base wall on which the sensor 4 is arranged. In particular, the sensor 4 is arranged on an inner side of the sensor housing base 6.1.1 of this first, fixed sensor housing part 6.1.

[0037] The second sensor housing part 6.2 is / is flexibly arranged and mounted, in particular axially movable, relative to the first sensor housing part 6.1 by means of the spring element(s) 10. This second sensor housing part 6.2 can, for example, be designed as a metallic housing and as a measuring electrode of the sensor 4. In the example shown, an electrical component 12, for example a busbar 14, of the electrical housing 2 adjoins the second sensor housing part 6.2. Depending on the type, the sensor 4 can be electrically coupled or connected to the electrical component 12 via an electrical line 16. Depending on the type of sensor 4, the second sensor housing part 6.2 can also be designed such that no further contact between the electrical housing 2 and / or one of the components 12 in the electrical housing 2, for example via a vehicle component, with the sensor 4 is necessary.

[0038] The type, structure, material, and / or arrangement of the sensor housing parts 6.1, 6.2 thus depend in particular on the type of sensor 4 used. For example, if the sensor 4 itself is designed as a multi-electrode sensor, for example a 2-electrode sensor for measuring conductivity, contact with a liquid, and / or permittivity, no additional contact with the sensor housing part(s) 6.1, 6.2 and / or with the component 12 and / or with the electrical housing 2 is necessary. Alternatively, the sensor 4 can be designed as a first sensor electrode, and the second sensor housing part 6.2, which is flexibly arranged relative to the sensor 4, and / or a region of the electrical housing 2, and / or one of the electrical components 12 in the electrical housing 2 can be designed as a further sensor electrode of the sensor 4.

[0039] The two sensor housing parts 6.1, 6.2 are / are designed, for example, as two U-shaped sensor housing shells, which are inserted into one another with their open ends to form a cavity 6.3 and are / are held flexibly and self-adjusting relative to one another by means of the spring elements 10. For example, one of the sensor housing parts 6.1 can be / are arranged radially inward and the other sensor housing part 6.2 radially outward. The sensor housing parts 6.1, 6.2 can be / are arranged flexibly overlapping one another in some areas. In particular, the two sensor housing parts 6.1, 6.2 can each be / are designed as a hollow, in particular annular-cylindrical or angular, component that is axially open on one side.

[0040] The first sensor housing part 6.1 has, for example, a particularly hollow-cylindrical, associated housing wall 6.1.3, which forms an inner wall 6.4 of the sensor housing 6. The second sensor housing part 6.2 has, for example, a particularly hollow-cylindrical, associated housing wall 6.2.2, which forms an outer wall 6.5 of the sensor housing 6. Both sensor housing parts 6.1, 6.2 can each have a sensor housing base 6.1.1, 6.2.1, in particular a radial base wall.

[0041] Additionally, particularly depending on the type of sensor 4, the axially movable second sensor housing part 6.2 can be adjacent to, or arranged and secured to, the busbar 14. Alternatively, the second sensor housing part 6.2 can be formed by a portion of the busbar 14 itself, in particular a shell-shaped receptacle of the busbar 14, and this busbar 14 can be mounted axially movable relative to the first sensor housing part 6.1.

[0042] In addition, a distance limiter 18 can be provided to limit the axial compensation distance 102. The distance limiter 18 can be formed, for example, as at least one recess 18.1, in particular an axial groove, in one of the sensor housing walls 6.2.2 of the second sensor housing part 6.2, into which a guide element 18.2, for example a guide pin, a guide lug, a guide pin, a guide bolt, or the like, protrudes radially from the other sensor housing wall 6.1.3 of the first sensor housing part 6.1, engages, or vice versa.

[0043] Fig.Figure 2 shows a schematic, partially transparent perspective view of the device 1 for monitoring the electrical housing 2. The electrical housing 2 is / is designed, for example, in a trough-shaped or bowl-shaped manner and has a housing base 2.1 into which a liquid can enter and collect. The sensor 4 is / is arranged and fixed to this housing base 2.1, as described above. The sensor 4 is / is coupled to the busbar 14 via the electrical line 16.

[0044] The respective spring element 10 is / is designed in particular as a preload spring and can have such a spring force that it holds the two sensor housing parts 6.1, 6.2 in a self-adjusting manner in the axial compensation distance 102 when mounted in an assembly space 20 between the housing base 2.1 to be monitored and the electrical component 12 opposite this housing base 2.1, in particular the busbar 14.

[0045] The sensor 4 can, for example, be pre-assembled on the electrical component 12, in particular the busbar 14, and mounted together with it in the mounting space 20 of the electrical housing 2.

[0046] Due to its axial tolerance compensating function (also called level compensating function) and due to its flexible attachment of the sensor-guiding or sensor-bearing first sensor housing part 6.1, in particular a lower sensor housing half, the sensor housing 6 can be arranged and fastened particularly preferably in an existing electrical housing 2, in particular an existing vehicle component, for example an existing housing of a vehicle battery, for example on the busbars 14 used for current conduction, and can be fastened thereto in a single assembly step, without the need for subsequent manual adjustment of the sensor position to tolerances (distance / angle) of the assembly for more reliable adjustment of the axial distance 100 of the sensor 4 to the housing base 2.1 of the electrical housing 2 to be monitored, in particular of a vehicle component to be monitored.For the optional permanent fastening of the sensor-carrying first sensor housing part 6.1 (= lower housing half) on the housing base 2.1 of the vehicle component to be monitored, in particular a battery, a permanent or detachable connection of the first sensor housing part 6.1 can optionally be provided, for example via magnetic forces in the case of vehicle components made of ferromagnetic materials or by attaching an adhesive element to the first sensor housing part 6.1 and / or to the housing base 2.1, so that these connect during assembly and additional sealing protection is possible.

[0047] The features and advantages described herein with respect to one embodiment may also relate to another embodiment described herein and vice versa. List of reference symbols 1 Device for monitoring an electrical enclosure for liquid ingress 2 electrical housings 2.1 Case bottom 4 Sensor for detecting liquid ingress 6 sensor housing 6.1 first sensor housing part 6.1.1 Sensor housing base 6.1.2 Sensor carrier 6.1.3 Housing wall 6.2 second sensor housing part 6.2.1 Sensor housing base 6.2.2 Housing wall 6.3 Cavity 6.4 Interior wall 6.5 Exterior wall 8 Magnet 10 spring element 10.1 Spring bearing 12 electrical components 14 Busbar 16 electrical cables 18 distance limiters 18.1 Recess 18.2 Guide element 20 assembly room 100 axial distance 102 Compensation distance

Claims

[1] Device (1) for monitoring an electrical housing (2) for liquid ingress with a sensor (4) for detecting the liquid ingress, wherein a multi-part flexible sensor housing (6) is provided, in which the sensor (4) is arranged on a sensor housing base (6.1.1), wherein the flexible sensor housing (6) is designed to hold the sensor (4) at a defined axial distance (100) from a housing base (2.1) of the electrical housing (2) to be monitored, characterized by that the sensor housing (6) comprises at least two sensor housing parts (6.1, 6.2) which are held in a self-adjusting manner at an axial compensation distance (102) from one another by means of at least one spring element (10) arranged between these two sensor housing parts (6.1, 6.2). [2] Device (1) according to claim 1, characterized by that a first sensor housing part (6.1) is arranged and held in a stationary manner on the housing base (2.1) to be monitored. [3] Device (1) according to claim 2, characterized by that a bottom wall of the first sensor housing part (6.1) forms the sensor housing bottom (6.1.1) on which the sensor (4) is arranged. [4] Device (1) according to claim 2 or 3, characterized by that a second sensor housing part (6.2) is arranged to be axially movable relative to the first sensor housing part (6.1) by means of the spring element (10). [5] Device (1) according to one of claims 1 to 4, characterized by that the two sensor housing parts (6.1, 6.2) are designed as two U-shaped sensor housing shells which are inserted into one another with their open ends to form a cavity (6.3) and are held flexibly and self-adjusting relative to one another by means of the spring element (10). [6] Device (1) according to claim 4 or 5, characterized bythat the axially movable second sensor housing part (6.2) is arranged on an electrical component (12) or is formed by a shell-shaped receptacle of the electrical component (12) and / or the electrical housing (2) and this electrical component (12) or the electrical housing (2) is mounted axially movable relative to the first sensor housing part (6.1). [7] Device (1) according to claim 6, characterized by that the spring element (10) is designed as a prestressing spring and has a spring force such that it holds the two sensor housing parts (6.1, 6.2) in a self-adjusting manner at an axial compensation distance (102) when mounted in an assembly space (20) between the housing base (2.1) to be monitored and the electrical component (12) opposite this housing base (2.1) and / or an opposite region of the electrical housing (2). [8] Device (1) according to claim 7, characterized bythat a distance limiter (18) is provided to limit the axial compensation distance (102). [9] Device (1) according to claim 8, characterized by that the distance limiter (18) is designed as at least one recess (18.1) in one of the housing walls (6.2.2) of one of the sensor housing parts (6.2), into which a guide element (18.2) protruding radially from a housing wall (6.1.3) of another sensor housing part (6.1) engages.

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