Coupling element for electrically coupling a high-voltage battery to a charging station

Abstract

The present invention relates to a coupling element (5) for electrically coupling a high-voltage battery of an electric vehicle with a charging station (1) for charging the high-voltage battery. The coupling element (5) is configured to cause the charging station (1) to charge the high-voltage battery according to the second charging mode.

Description

[0001] The present invention relates to a coupling element for electrically coupling a high-voltage battery of an electric vehicle to a charging station for charging the high-voltage battery.

[0002] Electric vehicles are becoming increasingly important in the automotive market. To provide electrical energy for an electric drivetrain, electric vehicles use a high-voltage battery. The high-voltage battery has particularly high demands in terms of capacity and performance—that is, its ability to deliver large amounts of energy as quickly as possible. For this reason, the high-voltage battery is often the most expensive component in an electric vehicle.

[0003] Electric batteries are subject to aging. This means that they lose capacity and performance. The aging process is caused, for example, by intermediate reactions in the electrolyte, deposits, and erosion on the electrodes. Intermediate reactions can depend, for example, on the battery temperature or the state of charge (SOC) of the high-voltage battery, with the intermediate reactions occurring more strongly at higher temperatures and with a higher SOC than at lower temperatures and with a lower SOC. High battery currents, for example, during charging or discharging, are further factors that accelerate the aging of high-voltage batteries.

[0004] Aging determines the service life of the high-voltage battery and, due to the high manufacturing costs, also significantly affects the value of the entire electric vehicle. In older electric vehicles, replacing the battery is therefore often a total loss. To keep the loss of value of an electric vehicle as low as possible, the aging process of the high-voltage battery must be slowed as much as possible. This can be achieved by operating the electric vehicle in a battery-friendly manner.

[0005] For this purpose, modern electric vehicles feature operating modes, also known as "Battery Care Modes" or "BCM," which ensure particularly battery-friendly operation, for example, by specifically limiting the performance of the high-voltage battery. One parameter of a BCM, for example, is the SOC, which is limited to 80%, for example, to avoid intermediate reactions.

[0006] Vehicle-specific limitations can be easily integrated into the development of electric vehicles. For older electric vehicles, retrofitting a BCM is only possible via a complex update of the electric vehicle's operating software. Due to the high development costs for the software, this is not economically viable and therefore not easily implemented. Drivers of such electric vehicles therefore only have the option of using a charging station (EVSE) with a relatively low charging capacity, for example, a maximum of 50 kW, to charge their batteries in a battery-saving manner. In contrast to modern fast charging stations (HPC-EVSE), which can often provide a charging capacity of 350 kW or more. This is very cumbersome, especially because public 50 kW charging stations are now rare.

[0007] Conventional charging stations for electric vehicles are designed to charge the high-voltage battery as efficiently as possible while avoiding overloading the high-voltage battery. To achieve this, the charging station regularly checks the high-voltage battery's charge level in order to gradually reduce the charging power at a critical charge level, for example, around 80%. In other words, the remaining 20% ​​of the high-voltage battery is charged at a lower charging power, particularly to prevent overheating and overcharging of the high-voltage battery. This process occurs automatically, so the user of the charging station has no way of influencing this protective mechanism.From the documents KR 10 2016 046 481A and US 10 071 648 B1, various methods for operating charging stations are known in which a charging current is specifically reduced depending on the state of charge in order to avoid overloading the high-voltage battery.

[0008] Existing fast-charging stations have the disadvantage that they are inadequately implemented to prevent the aging of the high-voltage battery during charging phases below a state of charge of 80%. The operator of the electric vehicle has no way of influencing the charging process.

[0009] It is therefore an object of the present invention to eliminate, or at least partially eliminate, the disadvantages described above in a charging process for charging a high-voltage battery of an electric vehicle. In particular, the object of the present invention is to provide a coupling element for electrically coupling a high-voltage battery of an electric vehicle to a charging station, which reduces the aging rate of the high-voltage battery in a simple and cost-effective manner.

[0010] The above object is achieved by the patent claims. Accordingly, the object is achieved by a coupling element for electrically coupling a high-voltage battery of an electric vehicle to a charging station for charging the high-voltage battery, having the features of independent claim 1. Further features and details of the invention emerge from the subclaims, the description, and the drawings.

[0011] According to the invention, this object is achieved by a coupling element for electrically coupling a high-voltage battery of an electric vehicle to a charging station for charging the high-voltage battery. According to the invention, the coupling element is designed to cause the charging station to charge the high-voltage battery according to the second charging mode. Preferably, the coupling element has a first coupling plug adapter for mechanically and electrically coupling to a charging station plug adapter of the charging station. Alternatively, the first coupling plug adapter is designed for mechanically and electrically coupling to a vehicle plug adapter of the electric vehicle.

[0012] According to the invention, the coupling element is designed to provide at least two technical functions. First, the coupling element is designed to establish an electrical connection between the electric vehicle and the charging station, such that the high-voltage battery of the electric vehicle can be charged by the charging station. Second, the coupling element is designed to cause the charging station to charge the high-voltage battery in the second charging mode. Within the scope of the invention, this also means that the charging station can be caused via the coupling element to charge the high-voltage battery according to the second charging mode, i.e., with a lower charging power than the electric vehicle would normally request from the charging station, so that the high-voltage battery is charged more gently.

[0013] The charging station can be operated, for example, according to a method for operating a charging station for charging a high-voltage battery of an electric vehicle. The method comprises: - Providing a first charging mode for charging the high-voltage battery and a second charging mode, which can be selected as an alternative to the first charging mode, for charging the high-voltage battery by a control device of the charging station, - Registration of a selection of the second charging mode by the control device, - Determination of a power requirement of the electric vehicle for charging the high-voltage battery by the control device, - Setting a target charging power that is reduced compared to the power requirement by the control device depending on the power requirement of the electric vehicle and a predefined charging limit specification of the second charging mode, and - Provision of the target charging power for charging the high-voltage battery by the control device.

[0014] The charging station has a control device for controlling the charging station and for monitoring and controlling the charging process of the high-voltage battery. The control device is preferably designed according to a conventional control device for charging stations and can differ from conventional control devices, for example, at least in terms of the operating software used.

[0015] The control device provides multiple charging modes for charging the high-voltage battery. For selecting the charging mode, a button, a touchscreen with a control panel, a communication interface for communicating with a mobile phone app, or the like can be provided. The control device provides at least the first charging mode and the second charging mode as charging modes. Preferably, the control device provides one or more additional charging modes as alternatives.

[0016] A charging mode is preferably configured to charge the high-voltage battery across a predefined or at least definable state-of-charge spectrum. For example, the first charging mode and / or the second charging mode can be configured to charge the high-voltage battery between an SOC of 50% and 100%. Preferably, the first charging mode is configured to charge the high-voltage battery across the entire state-of-charge spectrum of the high-voltage battery.

[0017] Furthermore, the first charging mode and / or the second charging mode are preferably configured to provide the charging power depending on one or more charging factors. Charging factors can be, for example, a state of charge of the high-voltage battery or a battery temperature of the high-voltage battery. Accordingly, it can be provided, for example, that the charging power is reduced starting at a predefined SOC or below a lower threshold temperature in order to prevent overloading of the high-voltage battery and thus accelerated aging. This is also referred to as "SOC-dependent charging power" within the scope of the invention.

[0018] The first charging mode can, for example, be configured as a fast-charging mode, in which the control device charges the high-voltage battery up to a predefined SOC and / or above a predefined lower threshold temperature, with a relatively high charging power, for example, 200 kW, 250 kW, or more. Starting at the predefined SOC, the charging power can then be reduced.

[0019] The second charging mode is preferably designed as a battery protection mode, in which the control device charges the high-voltage battery up to a predefined SOC in the most battery-friendly way possible. According to the invention, it can be provided that a maximum SOC achievable with the second charging mode is lower than a maximum SOC achievable with the first charging mode. The second charging mode is designed as an alternative to the first charging mode, so that charging to a specific SOC can be carried out with both the first charging mode and the second charging mode. The SOC-dependent charging power of the second charging mode can, for example, be a percentage value, for example 20%, or an absolute value, for example 30 kW, lower than the SOC-dependent charging power of the first charging mode. With a percentage value, the curve of the SOC-dependent charging power is flatter than with an absolute value.For example, if the SOC-dependent charging power in the first charging mode is 150 kW, the SOC-dependent charging power provided for the same SOC in the second charging mode can be 120 kW.

[0020] When the charging station user transmits their charging mode selection to the charging station, the control device registers this. If the user selects the second charging mode for battery-saving charging of the high-voltage battery, this is registered by the control device. Upon successful registration, the control device activates the second charging mode.

[0021] To implement the second charging mode, the control device determines the power requirement of the electric vehicle for charging the high-voltage battery. This can be done, for example, by briefly providing the maximum available charging power and analyzing the charging power actually demanded by the electric vehicle. This power requirement can, for example, correspond to a maximum possible power requirement of the electric vehicle. Alternatively, the power requirement can also be determined via a data interface to the electric vehicle, such as via radio, Bluetooth, Wi-Fi, the charging cable, or the like. The control device of the charging station can, for example, communicate with a vehicle control device of the electric vehicle via the data interface.The power requirement can, for example, be a SOC-dependent power requirement, which, for example, becomes lower as the SOC increases, starting from a predefined SOC.

[0022] Based on the determined power requirement and the predefined charging limit specification for the second charging mode, the control device determines the target charging power. The predefined charging limit specification specifies, for example, what percentage of the power requirement the target charging power should represent, for example, 80%, which corresponds to a 20% reduction in the power requirement. Alternatively, the predefined charging limit specification can specify a fixed value, for example, 30 kW, by which the charging limit specification should be reduced in order to maintain the target charging power. The target charging power thus specifies the charging power with which the high-voltage battery is to be charged in the second charging mode. If the charging power depends on the SOC, the target charging power is preferably also dependent on the SOC.

[0023] Finally, the control device provides the specified target charging power for charging the high-voltage battery. Since the target charging power is lower than the actual charging power due to the charging limit, the high-voltage battery is charged more slowly and gently than, for example, in the first charging mode, which is designed as a fast-charging mode.

[0024] The coupling element according to the invention has the advantage over conventional coupling elements that it ensures particularly gentle charging of the high-voltage battery using simple means and in a cost-effective manner. Since the target charging power is lower than the charging power, at least for a predefined state of charge spectrum, the charging process can be deliberately slowed down, thereby reducing the load on the high-voltage battery. In this way, the aging rate of the high-voltage battery can be reduced and the value retention of the electric vehicle can be improved. This advantageously extends the service life of the high-voltage battery. The coupling element according to the invention is particularly suitable for electric cars that do not have an integrated battery protection mode for charging the high-voltage battery.The operator of such an electric car can thus also use conventional charging stations that are not designed to implement the method according to the invention, thus also retaining the benefits of battery-saving charging. This avoids the complex and costly modernization of electric vehicles.

[0025] According to a preferred further development of the invention, a coupling element can be configured to automatically transmit a selection of the second charging mode to the charging station. This has the advantage of ensuring particularly battery-friendly charging using simple means and in a cost-effective manner, thus extending the service life of the high-voltage battery.

[0026] It is preferred according to the invention that the coupling element is designed as an intermediate adapter for electrically coupling a charging cable to the charging station or the electric vehicle. A coupling element designed as an intermediate adapter preferably has a second coupling plug adapter for mechanically and electrically coupling to a charging plug of a charging cable. The second coupling plug adapter is thus preferably designed according to the charging station plug adapter. In a coupling element designed as an intermediate adapter, the first coupling plug adapter and the second coupling plug adapter are preferably arranged in the same housing. The intermediate adapter preferably has a "CCS socket" and a "CCS plug". Additionally or alternatively, the intermediate adapter can also have a so-called "Type 2 socket" and a "Type 2 plug". Additionally or alternatively, the intermediate adapter has a so-called "Chademo socket" and a "Chademo plug".This has the advantage that charging is particularly gentle on the battery using simple means and in a cost-effective manner, thus further extending the service life of the high-voltage battery.

[0027] According to an alternative embodiment of the invention, the coupling element is designed as a charging cable for electrically coupling the high-voltage battery to the charging station. A coupling element designed as a charging cable preferably has a second coupling plug adapter for mechanically and electrically coupling to a vehicle plug adapter of the electric vehicle, as well as a multi-core cable via which the first coupling plug adapter is electrically coupled to the second coupling plug adapter. The charging cable preferably has a "CCS socket" and a "CCS plug." Additionally or alternatively, the charging cable can also have a so-called "Type 2 socket" and a "Type 2 plug." Additionally or alternatively, the charging cable has a so-called "Chademo socket" and a "Chademo plug."This has the advantage that charging is particularly gentle on the battery using simple means and in a cost-effective manner, thus further extending the service life of the high-voltage battery.

[0028] In a particularly preferred embodiment of the invention, the coupling element has a memory, a barcode, or a QR code, which can be read by a control device of the charging station to trigger the charging station to charge according to the second charging mode. This has the advantage of ensuring particularly battery-friendly charging using simple means and in a cost-effective manner, thus further extending the service life of the high-voltage battery.

[0029] The coupling element preferably has a switch, pushbutton, or button via which the second charging mode can be selected. Using the switch, pushbutton, or button, the user of the coupling element can, for example, actively set whether the second charging mode should be requested or not. The coupling element eliminates the need for manual input of the second charging mode selection at the charging station. Alternatively or additionally, the coupling element can have an element control device designed to communicate with the control device of the charging station. This has the advantage of ensuring particularly battery-friendly charging using simple means and in a cost-effective manner, thus further extending the service life of the high-voltage battery.

[0030] According to a preferred embodiment of the invention, the coupling element is designed to simulate an electric vehicle to the charging station that requests a lower charging power than the electric vehicle coupled to the charging station via the coupling element. Thus, the charging station provides a target charging power that corresponds to the simulated requested charging power and is thus lower than the target charging power requested by the electric vehicle. This has the advantage of ensuring particularly battery-friendly charging using simple means and in a cost-effective manner, thus further extending the service life of the high-voltage battery.

[0031] A charging station for charging the high-voltage battery preferably has a control device for controlling the charging station and for controlling and monitoring the charging process of the high-voltage battery. The control device is preferably designed according to a conventional control device for charging stations and can differ from conventional control devices, for example, at least in the operating software provided. The control device is designed to provide multiple charging modes for charging the high-voltage battery. For selecting the charging mode, the charging station can, for example, have a button, a touchscreen with a control panel, an interface for communicating with a mobile phone app, or the like.Furthermore, the control device is designed at least to register a selection of the second charging mode, to determine a power requirement of the electric vehicle for charging the high-voltage battery, to specify a target charging power for charging the high-voltage battery that is reduced compared to the power requirement as a function of the power requirement of the electric vehicle and a predefined charging limit specification of the second charging mode, and to provide the target charging power for charging the high-voltage battery.

[0032] A coupling element according to the invention for electrically coupling a high-voltage battery of an electric vehicle to a charging station is explained in more detail below with reference to the drawings. They show schematically: Fig. 1 a flowchart of a preferred embodiment of a method for charging a high-voltage battery, Fig. 2 in a diagram the determination of the target charging power, Fig. 3 in a front view a charging station for coupling with the coupling element, Fig. 4 shows a perspective view of a coupling element according to a preferred first embodiment of the invention, and Fig. 5 shows a perspective view of a coupling element according to a preferred second embodiment of the invention.

[0033] Elements with the same function and mode of action are listed in the Fig. 1 to 5 are each provided with the same reference numerals.

[0034] In Fig. 1, the preferred embodiment of the method for charging a high-voltage battery is shown schematically in a flowchart. In a first method action 100, a control device 2 (cf. Fig. 3) a charging station 1 (cf. Fig. 3) several charging modes are available for charging a high-voltage battery of an electric car. Among the charging modes, there is at least a first charging mode and a second charging mode that can be used as an alternative to the first charging mode. In a second method action 200, the control device 2 registers the selection of the second charging mode for charging the high-voltage battery. The selection is made by a coupling element 5 according to the invention (see FIG. Fig. 4 and Fig. 5). In a third process action 300, the control device 2 determines a power requirement P A (cf. Fig. 2) of the electric vehicle to charge the high-voltage battery. The power requirement P A is preferably dependent on the state of charge SOC of the high-voltage battery.

[0035] In a fourth method action 400, the control device 2 sets, depending on the power requirement P Aof the electric vehicle and a predefined charging limit specification of the second charging mode compared to the power requirement P A reduced target charging power P S The predefined charging limit specification determines the extent to which the power requirement P A should be reduced in order to achieve the target charging power P S The predefined charging limit specification is therefore preferably predefined in such a way that a target charging power P S which ensures battery-friendly charging of the high-voltage battery. In a fifth process action 500, the control device 2 sets the target charging power P S ready to charge the high-voltage battery. In other words, the high-voltage battery is charged with a lower charging power than the power requirement P A loaded.

[0036] Fig. 2 shows the determination of the target charging power P Sschematically in a diagram. The maximum charging power P that can be provided by charging station 1 M is shown as the upper horizontal line, since the maximum charging power P M is independent of the state of charge SOC of the high-voltage battery. A power demand curve P A of the electric car depends on a characteristic and the state of charge (SOC) of the high-voltage battery. The diagram shows that the power requirement P A initially increases with an increasing state of charge SOC of the high-voltage battery up to a lower state of charge SOC and then decreases with a further increase in the state of charge SOC of the high-voltage battery. A test charging power P that can be determined during the implementation of the method according to the invention T runs above the performance requirement P A with a constant distance to the power requirement P A. A target charging power P determined during the implementation of the method according to the invention S runs below the performance requirement P A with a constant distance to the power requirement P A .

[0037] In Fig. Figure 3 shows a schematic front view of the charging station 1 for coupling with the coupling element 5 of the invention. The charging station 1 has a station housing 8, on which several charging station plug-in adapters 3 and a control element 9 designed as a touchscreen are arranged. The control device 2 is arranged within the station housing 8.

[0038] Fig. Figure 4 shows the coupling element 5 according to the preferred first embodiment of the invention schematically in a perspective view. The coupling element 5 is designed as a charging cable 6 and has a first coupling plug adapter 4, which is electrically coupled to a second coupling plug adapter 10 of the coupling element 5 via a cable 11 of the coupling element 5. An element control device 12 is arranged on the first coupling plug adapter 4. The element control device 12 can be designed to transmit the selection of the second charging mode to a charging station 1, so that the charging station 1 can charge the high-voltage battery according to the target charging power P S Alternatively or additionally, the element control device 12 can be designed to determine from a power requirement P A of the electric vehicle using the predefined charging limit specification a reduced target charging power P Sand as a simulated performance requirement P A to charging station 1 so that charging station 1 can charge the high-voltage battery according to the simulated power requirement P A loads.

[0039] In Fig. Figure 5 schematically illustrates the coupling element 5 according to the preferred second embodiment of the invention in a perspective view. The second embodiment differs from the first embodiment in particular in that the coupling element 5 is designed as an intermediate adapter 7. Accordingly, the first coupling plug adapter 4 and the second coupling plug adapter 10 are arranged in a common adapter housing 13. A cable 11 is thus not present. List of reference symbols 1 charging station 2 Control device 3 charging station plug adapters 4 first coupling plug adapter 5 coupling element 6 charging cables 7 intermediate adapters 8 station housings 9 Control panel 10 second coupling plug adapter 11 cables 12 Element control device 13 adapter housing 100 first procedural action 200 second procedural action 300 third procedural action 400 fourth procedural action 500 fifth procedural action P Performance P A Performance requirement P M maximum charging power P S Target charging power P T Test charging power SOC state of charge QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] KR 10 2016 046 481A

[0007] US 10 071 648 B1

[0007]

Claims

[1] Coupling element (5) for electrically coupling a high-voltage battery of an electric vehicle to a charging station (1) for charging the high-voltage battery, characterized by that the coupling element (5) is designed to cause the charging station (1) to charge the high-voltage battery according to the second charging mode. [2] Coupling element (5) according to claim 1, characterized by that the coupling element (5) is designed to automatically transmit a selection of the second charging mode to the charging station (1). [3] Coupling element (5) according to claim 1 or 2, characterized by that the coupling element (5) is designed as an intermediate adapter (7) for electrically coupling a charging cable (6) to the charging station (1) or the electric vehicle. [4] Coupling element (5) according to claim 1 or 2, characterized by that the coupling element (5) is designed as a charging cable (6) for electrically coupling the high-voltage battery to the charging station (1). [5] Coupling element (5) according to one of the preceding claims, characterized by that the coupling element (5) has a memory, a barcode or a QR code which can be read by a control device (2) of the charging station (1) in order to cause the charging station (1) to charge according to the second charging mode. [6] Coupling element (5) according to one of the preceding claims, characterized by that the coupling element (5) has a switch, button or knob via which the second charging mode can be selected. [7] Coupling element (5) according to one of the preceding claims, characterized by that the coupling element (5) is designed to simulate an electric vehicle to the charging station (1) which requires a lower charging power than the electric vehicle coupled to the charging station (1) via the coupling element.

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