High-voltage electrical connection and electrically operated powertrain of a motor vehicle

Abstract

The invention relates to an electrical high-voltage connection (1) for a powertrain (10) of a motor vehicle (2), comprising an HV plug (4) connected to an electrical line (3) and a corresponding HV socket (5) in which the HV plug (4) is detachably received, wherein the HV plug (4) is enclosed by a deep-drawn cover plate (6) fixed to the HV socket (5).

Description

[0001] The present invention relates to an electrical high-voltage connection for a drive train of a motor vehicle, comprising an HV connector connected to an electrical line and a corresponding HV socket in which the HV connector is releasably received. The invention further relates to an electrically operable drive train of a motor vehicle.

[0002] Electric motors are increasingly being used to power motor vehicles, creating alternatives to combustion engines that require fossil fuels. Considerable efforts have already been made to improve the everyday suitability of electric drives and also to provide users with the same level of driving comfort they are accustomed to.

[0003] A detailed description of an electric drive can be found in an article in the magazine ATZ, Volume 113, May 2011, pages 360-365, by Erik Schneider, Frank Fickl, Bernd Cebulski, and Jens Liebold, titled "Highly Integrated and Flexible Electric Drive Unit for E-Vehicles." This article describes a drive unit for a vehicle axle that includes an electric motor arranged concentrically and coaxially with a bevel gear differential. Such drive units are also referred to as e-axles or electrically operated drivetrains.

[0004] In addition to purely electric drivetrains, hybrid drivetrains are also known. Such drivetrains in a hybrid vehicle typically comprise a combination of an internal combustion engine and an electric motor, enabling purely electric operation—for example, in urban areas—while maintaining sufficient range and availability, particularly on long-distance journeys. Furthermore, in certain operating situations, it is possible to use both the internal combustion engine and the electric motor simultaneously. With this increasing electrification of modern drivetrains in the automotive industry, the need to transmit HV power within the vehicle is growing, for example, between the battery, inverter, and electric motor, as well as to auxiliary units such as the air conditioning compressor, oil pumps, or vacuum pumps.In order to make installation and service as simple and safe as possible, HV connectors are increasingly being installed in electrically operated vehicles.

[0005] The publication DE 10 2021 208 929 A1 shows an electrical connection for a drive train of a motor vehicle, comprising a plug connected to an electrical line and a corresponding socket in which the plug is detachably received, wherein the plug is housed by a metal cover screwed to the socket.

[0006] A deep-drawn cover plate for electromagnetic shielding is known from DE 10 2021 123 635 A1.

[0007] The object of the invention is to provide an improved high-voltage electrical connection. Furthermore, the object of the invention is to realize an optimized electrically operable drive train for a motor vehicle.

[0008] This object is achieved by an electrical high-voltage connection for a drive train of a motor vehicle, comprising an HV plug connected to an electrical line and a corresponding HV socket in which the HV plug is releasably received, wherein the HV plug is housed by a deep-drawn cover plate fixed to the HV socket.

[0009] This provides the advantage that the cover plate provides additional mechanical protection for the high-voltage connection in the event of an accident and the resulting forces acting on it. The stability of the deep-drawn cover plate better protects the HV connector from the forces exerted in the event of a crash, allowing greater freedom in the placement of the electrical components within the vehicle structure.

[0010] The cover plate also contributes to improved protection against other environmental influences, such as moisture, splash water, etc.

[0011] Furthermore, the cover plate can contribute to improved shielding of electromagnetic radiation in the area of ​​the high-voltage connection.

[0012] The HV connector is essentially molded from an electrically non-conductive plastic, in which the electrical conductors and contacts are arranged. The HV socket is also essentially molded from an electrically non-conductive plastic, in which, for example, contacts and electrical conductors run.

[0013] According to an advantageous embodiment of the invention, the cover plate can be provided to cover the electrical line at least in sections. The advantage of this embodiment is that the protective area of ​​the cover plate can be extended to include the electrical line.

[0014] According to a further preferred development of the invention, the HV slot can also be provided with a cable guide for guiding the electrical cable. This can facilitate simplified assembly and secure positioning of the electrical cable at the HV slot. The cable guide is preferably formed integrally, in particular monolithically, with the HV slot.

[0015] Furthermore, according to a similarly advantageous embodiment of the invention, the cover plate can form a press connection with the electrical cable in the area of ​​the cable guide, thus securing the electrical cable to the cable guide. Furthermore, strain relief for the HV connector can be implemented in this way. This also further simplifies the assembly process, since the electrical cable can be secured in the same step as the cover plate is secured to the HV socket.

[0016] According to a further particularly preferred embodiment of the invention, it can be provided that the cover plate is designed in a shell-like manner, which has proven to be particularly advantageous with regard to the protective effect and cost-effective production.

[0017] Furthermore, the invention can also be further developed in such a way that the cover plate is fixed to the HV slot by means of at least one screw connection, which is particularly easy to install and safe and, due to the use of standard components, is also particularly cost-effective.

[0018] A screw connection, in particular, ensures secure and reliable fixation of the cover plate. Compared to other fastening methods such as clips or adhesives, a screw offers a robust mechanical connection that gives the cover plate a high level of stability. In automotive applications, vibrations caused by electrical or mechanical components can also occur. By using a screw connection, the cover plate is held securely in place, even when exposed to corresponding vibrations. A screw connection allows the cover plate to be easily removed and reattached, which facilitates maintenance and access to the electrical components underneath. In case of repairs, inspections, or adjustments to the high-voltage components, the cover plate can be quickly dismantled to ensure the required access.Once the work is completed, it can be reattached just as easily. Finally, screw connections also offer the possibility of quickly and easily removing the cover plate and replacing or adapting it as needed. This allows for great flexibility in the event of design changes, upgrades, or other requirements that require modification of the cover plate. It is possible to use different types of cover plates with different functions or features by simply attaching them to the corresponding screw connection.

[0019] In a likewise preferred embodiment of the invention, it can also be provided that the electrical cable extends out of the HV connector orthogonal to the plug-in direction of the connector. This allows, among other things, to simplify and clearen the cabling. Depending on the installation space situation, this can make it easier to lay, fasten and organize the cable, as it does not become tangled in the connector or come into conflict with other components. The lateral alignment of the cable also allows more effective strain relief to be achieved to ensure that the cable is not accidentally pulled out of the connector or placed under tensile stress, which could lead to damage or safety risks.

[0020] It may also be advantageous to further develop the invention such that the screw connection is oriented in the plug-in direction of the HV connector. By aligning the screw connection in the plug-in direction of the HV connector, additional stability and strength are ensured, since the screw in this orientation acts in direct line with the tensile force that occurs when the connector is inserted or removed. This further increases the stability of the fastening and reduces the risk of loosening or displacement of the cover plate. By orienting the screw connection in the plug-in direction of the HV connector, the tensile load on the cover plate can be minimized. Furthermore, a screw connection oriented in the plug-in direction of the HV connector can facilitate handling during installation or removal of the cover plate, since both processes can be coordinated and carried out more easily.Finally, a screw connection in the mating direction of the HV connector can also contribute to an aesthetically pleasing appearance, as the cover plate can appear smoother and more seamless, as the screw runs in the same orientation as the connector. This can be particularly important in applications where the external appearance of the high-voltage connection is important, such as in the automotive industry.

[0021] The object of the invention can further be achieved by an electrically operable drive train for a motor vehicle comprising an electrical high-voltage connection according to one of claims 1-8.

[0022] An electrically operable drive train comprises an electric machine and preferably a transmission arrangement coupled to the electric machine. The transmission arrangement and the electric machine can form a structural unit. This can be formed, for example, by means of a drive train housing in which the transmission arrangement and the electric machine are jointly accommodated. Alternatively, it would of course also be possible for the electric machine to have a motor housing and / or the transmission to have a transmission housing, in which case the structural unit can be achieved by fixing the transmission relative to the electric machine. The transmission housing is a housing for accommodating a transmission.Its task is to guide existing shafts via the bearings and to grant the wheels (and possibly cams) the degrees of freedom they require under all loads without hindering their rotational and possibly path-related motion, as well as to absorb bearing forces and support moments. A gearbox housing can be single- or multi-shell, i.e., undivided or split. In particular, the housing should also dampen noise and vibrations and be able to safely accommodate lubricant. The gearbox housing is preferably made of a metallic material, particularly preferably aluminum, gray cast iron, or cast steel, in particular by means of a primary forming process such as casting or die-casting.

[0023] The motor housing encloses the electric machine. A motor housing can also accommodate the control and power electronics. The motor housing can also be part of a cooling system for the electric machine and be designed in such a way that cooling fluid can be supplied to the electric machine via the motor housing and / or heat can be dissipated to the outside via the housing surfaces. Furthermore, the motor housing protects the electric machine and any electronics from external influences.

[0024] A motor housing can, in particular, be formed from a metallic material. Advantageously, the motor housing can be formed from a metallic cast material, such as die-cast aluminum, die-cast magnesium, gray cast iron, or cast steel.

[0025] In particular, the electric machine is dimensioned such that vehicle speeds greater than 50 km / h, preferably greater than 80 km / h, and especially greater than 100 km / h can be achieved. The electric motor particularly preferably has an output greater than 30 kW, preferably greater than 50 kW, and especially greater than 70 kW. It is further preferred that the electric machine provides speeds greater than 5,000 rpm, particularly preferably greater than 10,000 rpm, and most preferably greater than 12,500 rpm.

[0026] The electric drive train can be operated by means of a power electronics module, preferably in that the power electronics module conducts current into the electrically operable drive train, e.g. to a stator winding of the electric machine. The power electronics accommodated in an inverter housing can therefore be provided in particular for an electric machine of an electrically operable drive train of a motor vehicle. The power electronics is preferably a combination of various components which control or regulate a current to the electric machine of the axle drive train, preferably including the peripheral components required for this purpose, such as cooling elements or power supplies. In particular, the power electronics contains one or more power electronics components which are designed to control or regulate a current. These are particularly preferably one or more power switches, e.g. power transistors.The power electronics particularly preferably have more than two, particularly preferably three, separate phases or current paths, each with at least one dedicated power electronics component. The power electronics are preferably designed to control or regulate a power per phase with a peak power, preferably continuous power, of at least 10 W, preferably at least 100 W, particularly preferably at least 1000 W.

[0027] Finally, the invention can also be advantageously implemented such that the high-voltage electrical connection is located in an externally accessible area of ​​the drive train. Placing the high-voltage connection in an externally accessible area allows for easier access for maintenance and repair work. Technicians can more easily access the connection, for example, to perform an inspection, check cable connections, or make repairs if necessary. This facilitates maintenance and reduces potential downtime. An externally accessible high-voltage connection can also promote better heat dissipation through heat exchange with the surrounding air.

[0028] The invention will be explained in more detail below with reference to figures without limiting the general inventive concept.

[0029] It shows: Fig. 1 a high-voltage connection in an exploded view, Fig. 2 a high-voltage connection in the assembled state in a perspective view, Fig. 3 a cover plate of a high-voltage connection in a perspective view, Fig. 4 an electrically operated drive train of a motor vehicle in a schematic representation,

[0030] The Fig. 1-2 show an electrical high-voltage connection 1 for a drive train 10 of a motor vehicle 2, comprising an HV plug 4 made of a plastic and connected to two electrical lines 3 and a corresponding HV socket 5 in which the HV plug 4 is detachably received.

[0031] The HV connector 4 is enclosed by a deep-drawn cover plate 6 fixed to the HV connector slot 5, which is molded from a plastic material. This HV connector slot 5 extends from a housing 11, which can be, for example, a motor housing or inverter housing. The HV connector slot 5 is formed integrally with a part of the housing 11. The cover plate 6 also covers the electrical lines 3, at least in sections. The electrical line 3 extends out of the HV connector 4 orthogonally to the plugging direction 9 of the connector.

[0032] The HV slot 5 has a cable guide 7 for guiding the electrical cables 3, whereby the cover plate 6 forms a press connection with the electrical cables 3 in the area of ​​the cable guide 7, which can also be clearly seen from the overview of the Fig. 2-3. When mounted on the HV socket 5, the cable guide section 13 of the cover plate 6 presses the electrical lines 3 against the cable guide 7. The cable guide section 13 accommodates the outer contour of the electrical lines 3 and has a correspondingly double-arched cross-section. It is understood that the electrical lines 3 are surrounded by an insulating material.

[0033] The connector covering section 14 of the cover plate 6 spanning the HV connector 4 is also formed from two ring-section-like cross-sectional contours that are aligned with the double-curved cable guide sections.

[0034] The cover plate 6 is designed as a whole in a shell-like manner and is fixed to the HV socket 5 by means of at least one screw connection 8. For this purpose, the fastening tabs 12 are monolithically connected to the cover plate 6, which can then each be penetrated by a screw of the screw connection 8, which is clearly evident from the Fig. 3. The screw connection 8 is oriented in the plugging direction 9 of the HV connector 4.

[0035] Fig. 4 shows an electrically operable drive train 10 for a motor vehicle 2 comprising an electric machine 15 with an electrical high-voltage connection 1, as shown in the Fig. 1-3. The electrical high-voltage connection 1 is arranged in an externally accessible area of ​​the drive train 10.

[0036] The invention is not limited to the embodiments illustrated in the figures. The above description is therefore not to be considered restrictive, but rather explanatory. The following claims are to be understood in such a way that a stated feature is present in at least one embodiment of the invention. This does not exclude the presence of further features. Where the claims and the above description define 'first' and 'second' features, this designation serves to distinguish between two similar features without establishing a priority. List of reference symbols 1 high-voltage connection 2 motor vehicles 3 Line 4 HV connectors 5 HV slot 6 cover plate 7 Cable routing 8 screw connection 9 Plug-in direction 10 Drivetrain 11 housings 12 mounting tabs 13 Cable routing section 14 Connector cover section 15 electric machine

Claims

[1] Electrical high-voltage connection (1) for a drive train (10) of a motor vehicle (2), comprising an HV plug (4) connected to an electrical line (3) and a corresponding HV socket (5) in which the HV plug (4) is releasably received, wherein the HV plug (4) is housed by a deep-drawn cover plate (6) fixed to the HV socket (5). [2] High-voltage connection (1) according to claim 1, characterized by that the cover plate (6) covers the electrical line (3) at least in sections. [3] High-voltage connection (1) according to claim 1 or 2, characterized by that the HV slot (5) has a cable guide (7) for guiding the electrical cable (3). [4] High-voltage connection (1) according to claim 3, characterized by that the cover plate (6) forms a press connection with the electrical cable (3) in the area of ​​the cable guide (7). [5] High-voltage connection (1) according to one of the preceding claims, characterized by that the cover plate (6) is designed like a shell. [6] High-voltage connection (1) according to one of the preceding claims, characterized by that the cover plate (6) is fixed to the HV slot (5) by means of at least one screw connection (8). [7] High-voltage connection (1) according to one of the preceding claims, characterized by that the electrical line (3) extends out of the HV plug (4) orthogonally to the plugging direction (9). [8] High-voltage connection (1) according to one of claims 6-7, characterized by that the screw connection (8) is oriented in the plug-in direction (9) of the HV connector (4). [9] Electrically operable drive train (10) for a motor vehicle (2) comprising an electrical high-voltage connection (1) according to one of the preceding claims. [10] Drive train (10) according to claim 9, characterized bythat the electrical high-voltage connection (1) is arranged in an externally accessible area of ​​the drive train (10).

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