Plug-in system with locking element and safety circuit

Abstract

The disclosure relates to a plugging system (100) for securely inserting a plug (101) into a mating plug (102), wherein the plugging system (100) comprises: a mating plug (102); a plug (101) that can be inserted into the mating plug (102); a locking element (110) which, when the plug (101) is inserted into the mating plug (102), can be moved from a first locking position (111) to a second locking position (112), wherein the locking element (110) in the second locking position (112) causes the plug (101) inserted into the mating plug (102) to be locked; and a safety circuit (120) which is open in the first locking position (111) and closed in the second locking position (112) to indicate the locking of the plug (101) inserted into the mating plug (102).

Description

Technical area

[0001] The present invention relates to a connector system with a locking element and safety circuit for securely plugging a plug into a mating connector, particularly for a connector for charging an electric vehicle. The invention particularly relates to an interlock protection device with variable plug-in timing. State of the art

[0002] CPAs (“Connector Position Assurance”) are designed to prevent a plug that is locked onto a mating plug from accidentally becoming detached from the mating plug, which can happen, for example, due to vibrations, temperature-related expansion or shrinkage, pulling on a cable housed in the plug housing, or other mechanical influences. The CPA is the last element to be operated and is responsible for locking the plug to its counterpart. To protect people when operating such a connector system, the connector system should only be released after the connection has been fully locked. To do this, it must be checked whether the plug is fully inserted, and only then may the high-voltage contacts be released so that current can flow. Description of the invention

[0003] An object of the invention is therefore to provide a suitable plug-in system with which it can be reliably and easily detected whether the plug connection is locked or not, in particular for plug-in systems requiring a CPA lock, such as plug-in systems used for charging electric vehicles.

[0004] The object is achieved by the subject matter of the independent claims. Advantageous developments of the invention are specified in the dependent claims, the description, and the accompanying figures.

[0005] The inventive solution is based on the idea of ​​using a safety circuit to detect whether a lock is present or not.

[0006] By means of an integrated signal line in the connector, which releases the circuit (interlock mechanism or locking mechanism, e.g. in HV (high-voltage) connector systems), it can be checked whether the connector is fully inserted. Only then are the high-voltage contacts released, i.e. current flows. The interlock mechanism is integrated, for example, in the CPA. The CPA can only be actuated when the connector is locked, which corresponds to a general OEM specification. This ensures that the connector is in position and the HV contacts are in position. The interlock mechanism can also be integrated in the lever or slide, and the CPA could then be omitted, since the safety circuit takes over the function of the CPA.

[0007] The invention presented here offers the following advantages: The HV line is only released after the connector is fully locked. The safety circuit allows monitoring of the mechanical connection, thus reducing the risk of human error. The safety circuit can be disconnected well before the HV contacts are disconnected, allowing for a cool-down time requirement of approximately 3 seconds before the HV contacts are touchable.

[0008] The invention can be used in all connector systems that include an electronic signal circuit and some form of locking mechanism. The connector system can also be retrofitted to connectors that were developed without an interlock mechanism and later require one. The interlock mechanism has a variable, i.e., not fixed, mating timing and can be integrated into the movable locking element or the CPA.

[0009] According to a first aspect, the object described above is achieved by a plug-in system for securely plugging a plug into a mating plug, the plug-in system comprising: a mating plug; a plug that can be plugged into the mating plug; a locking element that, when the plug is plugged into the mating plug, is movable from a first locking position into a second locking position, the locking element locking the plug plugged into the mating plug in the second locking position; and a safety circuit that is open in the first locking position and closed in the second locking position to indicate the locking of the plug plugged into the mating plug.

[0010] Such an interlock mechanism with a locking element and safety circuit ensures secure insertion of the plug into the mating connector. Furthermore, the presence of the locking mechanism can be easily and automatically verified, since a current only flows when the locking mechanism is present, indicating the presence of the locking mechanism. This eliminates work steps in which the position of the locking element must be visually checked, for example, using a DMC code.

[0011] According to an exemplary embodiment of the plug-in system, the locking element can only be moved from the first locking position to the second locking position when the plug has been plugged into the mating plug; and the safety circuit is only closed when the locking element has been moved from the first locking position to the second locking position.

[0012] Such an interlock mechanism has a variable plug-in timing in which the various steps for establishing a secure plug-in connection are decoupled from one another.

[0013] According to an exemplary embodiment of the plug-in system, the locking element and / or the safety circuit is designed to provide a plug position assurance (CPA) for ensuring locking of the plug to the mating plug.

[0014] This offers the technical advantage that a CPA (Connector Position Assurance) can be implemented with both the locking element and the safety circuit.

[0015] According to an exemplary embodiment of the plug-in system, the mating connector comprises a mating connector housing and the plug comprises a plug housing; wherein the safety circuit is arranged outside the mating connector housing and outside the plug housing.

[0016] This offers the technical advantage that the plug contacts of the plug and mating plug, with their high-voltage potentials, cannot interfere with the safety circuit.

[0017] According to an exemplary embodiment of the plug-in system, the safety circuit comprises a first contact element and a second contact element; wherein the first contact element establishes an electrical connection with the second contact element when the safety circuit is closed.

[0018] An electrical connection can be easily established and broken using the two contact elements. The second contact element can be a pin, for example, and the first contact element can be a socket or plug into which the pin can be inserted to establish the electrical connection.

[0019] According to an exemplary embodiment of the plug-in system, one of the two contact elements is mounted in or on the locking element.

[0020] This means that a current flow in the safety circuit depends on the position of the locking element and can therefore safely indicate a lock.

[0021] According to an exemplary embodiment of the plug-in system, the second of the two contact elements is mounted in or on the mating connector.

[0022] This means that a current flow in the safety circuit depends on the position of the mating connector relative to the locking element and can therefore safely indicate that the connector inserted into the mating connector is locked.

[0023] According to an exemplary embodiment of the plug-in system, the second contact element is arranged in a housing chamber of the mating connector; and the first contact element is arranged in a housing chamber in a dome of the locking element. Instead of in a dome, the first contact element can also be arranged in another mechanical element of the locking element, for example, a rod-shaped element or a sleeve or the like, which shields and protects the first contact element from the environment.

[0024] This effectively protects the two contact elements against environmental influences that may occur when establishing the plug connection, for example for charging the electric vehicle.

[0025] According to an exemplary embodiment of the plug-in system, when the locking element is moved from the first locking position to the second locking position, the dome moves into the housing chamber of the mating connector in order to establish the electrical connection of the first contact element to the second contact element.

[0026] This means that the two contact elements are effectively protected against environmental influences even during the connection process.

[0027] According to an exemplary embodiment of the plug-in system, the locking element comprises a seal which is arranged on the dome and which, when the dome is inserted into the housing chamber of the mating connector, comes into contact with the housing chamber and seals the electrical connection of the first contact element to the second contact element against environmental influences outside the housing chamber.

[0028] The seal provides particularly effective sealing of the two contact elements so that they cannot become dirty and the safety circuit can reliably and durably indicate a lock. Short character description

[0029] The invention is described in more detail below using exemplary embodiments and the figures. They show: Fig. 1 a sectional view of a plug-mating plug interface with high-voltage contacts L1, L2, L3, N and an interlock interface arranged outside the plug-mating plug interface with safety circuit 120 of a plug system 100 according to the invention; Fig. 2 a side view of a locking element 110 according to the invention with an interlock mechanism; Fig. 3 a sectional view of a plug-in system 100 according to the invention in the unplugged state, in which the plug 101 is not plugged into the mating plug 102; Fig. 4 shows a sectional view of the plug-in system 100 according to the invention in the plugged-in but unlocked state, in which the plug 101 is plugged into the mating plug 102, but the locking element 110 is not in the second locking position 112; and Fig. 5 a sectional view of the plug-in system 100 according to the invention in the plugged and locked state, in which the plug 101 is plugged into the mating plug 102 and the locking element 110 is in the second locking position 112.

[0030] The figures are merely schematic representations and serve only to illustrate the invention. Identical or equivalent elements are provided with the same reference numerals throughout.

[0031] In the following detailed description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. It is understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention. The following detailed description, therefore, is not to be taken in a limiting sense. Further, it is to be understood that the features of the various embodiments described herein may be combined with one another unless specifically indicated otherwise.

[0032] The aspects and embodiments are described with reference to the drawings, where like reference numerals generally refer to like elements. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of one or more aspects of the invention. However, it may be apparent to one skilled in the art that one or more aspects or embodiments may be practiced with a lesser level of specific detail. In other instances, well-known structures and elements are shown in schematic form to facilitate describing one or more aspects or embodiments. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the concept of the present invention.

[0033] Fig. 1 shows a sectional view of a plug-mating plug interface with high-voltage contacts L1, L2, L3, N and an interlock interface with safety circuit 120 of a plug system 100 according to the invention, arranged outside the plug-mating plug interface.

[0034] In this example, the entire interface consists of two separate interfaces, the plug-mating plug interface with high-voltage contacts L1, L2, L3 and N, where Fig. 1 shows the top view of the mating connector 102 and the interlock interface with safety circuit 120. However, this is not necessary; both interfaces, ie the plug-mating connector interface with high-voltage contacts and the interlock interface with safety circuit 120, can be implemented as a single interface.

[0035] The plug-mating connector interface with high-voltage contacts L1, L2, L3, and N is shown in this example as a CCS (Combined Charging System) with the three HV conductors L1, L2, L3 and the neutral conductor N, which can be used for charging electric vehicles according to the CCS standard. However, any other plug-mating connector interface can also be used for the invention described here, for example, with fewer contacts. It is sufficient if the plug-mating connector interface establishes contact with its mating contact.

[0036] Both interfaces have their own sealing system, each separated from the other. This design is also not necessary. Alternatively, a single sealing system can be used that encompasses both interfaces and seals against environmental influences.

[0037] In Fig. 1 shows the mating connector 102 of the plug-to-mating connector interface, into which a corresponding connector 101, which is not shown here, can be plugged.

[0038] Furthermore, Fig. 1 the contact elements 121 of the safety circuit 120 can be seen, which can be inserted into counter-contact elements 122 (not shown here) when the safety circuit 120 is closed.

[0039] Fig. 2 shows a side view of a locking element 110 according to the invention with an interlock mechanism.

[0040] The locking element 110 has the function of a CPA (Connector Position Assurance). Fig. 2, the interlock bridge with the contacts 122, 121 is contained in the locking element 110 or the CPA. The interlock bridge, which comprises the two electrical contact elements 122 and 121 and establishes the electrical contact bridge between the two contact elements 122, 121 when the safety circuit 120 is closed, is contained in a housing chamber 116 of an interlock dome 117 of the CPA or the locking element 110 and in Fig. 2 shown only in dashed lines.

[0041] The Interlock Dome 117 has Fig. 2 a separate seal 115, which seals the interlock dome 117 with the interlock bridge against external environmental influences when the CPA is actuated. This seal 115 is an optional element. Fig. 2 only the interlock dome 117, which contains the contact chamber 116 and the interlock bridge contained therein, is shown.

[0042] The interlock bridge is the connection between the two electrical contacts 122, 121, which is created when the CPA is closed. Fig. 2, only the contact element 122 is shown in dashed lines, which is located in the contact chamber 116. The mating contact element 121 is located in a similar contact chamber 123 of the mating connector, as described below for the Fig. 3 to 5 are described in more detail.

[0043] Fig. 3 shows a sectional view of a plug-in system 100 according to the invention in the unplugged state, in which the plug 101 is not plugged into the mating plug 102.

[0044] When the connector system 100 is unplugged, both the high-voltage contacts L1, L2, L3, N and the interlock with the contact elements 122, 121 have no contact.

[0045] The interlock here consists of the two contact elements 122, 121, which do not contact each other, so that no current flows in the safety circuit 120.

[0046] As from Fig. 3, the plug 101 is not plugged into the mating plug 102, so that the locking element 110 cannot be actuated and no electrical connection can be established between the contacts 122 of the locking element 110 and the contacts 121 on the mating plug 102.

[0047] If the connector 101 is plugged in but the CPA is still open, the safety circuit 120 with interlock is not yet closed, as in Fig. 4 shown.

[0048] Only when the CPA is actuated and it is thus ensured that the plug 101 is fully inserted and cannot be removed without unlocking the CPA, the interlock is in the end position and the safety circuit 120 is closed, as shown in Fig. 5 shown.

[0049] Fig. 4 shows a sectional view of the plug-in system 100 according to the invention in the plugged but unlocked state, in which the plug 101 is plugged into the mating plug 102, but the locking element 110 is not in the second locking position 112. Fig. 5 shows the connector system 100 in the plugged and locked state, in which the plug 101 is plugged into the mating plug 102 and the locking element 110 is in the second locking position 112.

[0050] The plug-in system 100 serves for the secure plugging of a plug 101 into a mating plug 102, as already described above for the Fig. 1 to 3.

[0051] The plug-in system 100 comprises a mating plug 102 and a plug 101 that can be plugged into the mating plug 102.

[0052] The plug-in system 100 comprises a locking element 110, also referred to here as CPA, which, when the plug 101 is plugged into the mating plug 102, is movable from a first locking position 111 into a second locking position 112, wherein the locking element 110 in the second locking position 112 locks the plug 101 plugged into the mating plug 102.

[0053] The locking element 110 is in Fig. 4 in the first locking position 111 and in Fig. 5 in the second locking position 112.

[0054] The connector system 100 further comprises a safety circuit 120, which is open in the first locking position 111 and closed in the second locking position 112 to indicate the locking of the plug 101 inserted into the mating plug 102. The flow of current through the safety circuit 120, which can be detected by a suitable measuring element, indicates the locking. A control unit can monitor the current flow through the safety circuit 120 and take appropriate measures.

[0055] The locking element 110 can only be moved from the first locking position 111 into the second locking position 112 when the plug 101 has been plugged into the mating plug 102, which is the transition from Fig. 3 to Fig. 4 illustrates this.

[0056] Furthermore, the safety circuit 120 is only closed when the locking element 110 has been moved from the first locking position 111 to the second locking position 112, which is the transition from Fig. 4 to Fig. 5 illustrates this.

[0057] Such an interlock mechanism results in variable plug-in timing, in which the various steps for establishing a secure plug-in connection are decoupled from each other, as can be seen from the transitions between the Fig. 3, Fig. 4 and Fig. 5.

[0058] The locking element 110 and / or the safety circuit 120 can be designed to provide a connector position assurance (CPA) to ensure locking of the connector 101 to the mating connector 102.

[0059] This allows a CPA (Connector Position Assurance) function to be implemented by both the locking element 110 and the safety circuit 120. The flow of current through the safety circuit 120 thus replaces visual monitoring of the locking element 110 or the CPA, for example, by reading a DMC code on the CPA.

[0060] The mating connector 102 comprises a mating connector housing 103 and the connector 101 comprises a connector housing 104, as shown in the Fig. 3 to 5.

[0061] The safety circuit 120 can be arranged outside the mating connector housing 103 and outside the connector housing 104, as shown in the Fig. 1 and 3 to 5. Alternatively, the safety circuit 120 can also be arranged within the mating connector housing 103 and / or within the connector housing 104.

[0062] The safety circuit 120 comprises a first contact element 122 and a second contact element 121, as shown in the Fig. 1 to 5. When the safety circuit 120 is closed, the first contact element 122 can establish an electrical connection with the second contact element 121, thus indicating a locking of the plug 101 with the mating plug 102.

[0063] One of the two contact elements 122, 121 can be mounted in or on the locking element 110, as shown in the Fig. 1 to 5, where the first contact element 122 is attached to the locking element 110.

[0064] The second of the two contact elements 122, 121 can be mounted in or on the mating connector 102, as shown in the Fig. 1 to 5, where the second contact element 121 is attached to the mating connector 102.

[0065] The second contact element 121 can be arranged, for example, in a housing chamber 123 of the mating connector 102. The first contact element 122 can be arranged, for example, in a housing chamber 116 in a dome 117 of the locking element 110, as shown in the Fig. 3 to 5.

[0066] The dome 117 can move into the housing chamber 123 of the mating connector 102 when the locking element 110 is moved from the first locking position 111 to the second locking position 112 in order to establish the electrical connection of the first contact element 122 with the second contact element 121, as shown in the Fig. 4 and Fig. 5 shown.

[0067] The locking element 110 can optionally comprise a seal 115 which is arranged on the dome 117 and which, when the dome 117 is retracted into the housing chamber 123 of the mating connector 102, comes into contact with the housing chamber 123 and seals the electrical connection of the first contact element 122 with the second contact element 121 against environmental influences outside the housing chamber 123, as shown in the Fig. 4 and Fig. 5 shown. LIST OF REFERENCE SYMBOLS 100 plug-in system 101 plugs 102 Mating connector or interface 103 Mating connector housing 104 connector housings 110 locking element or CPA 111 first locking position 112 second locking position 114 locking element 115 Seal 116 Housing chamber of the locking element 117 Dome or web of the locking element 120 safety circuit 121 second contact element 122 first contact element 123 Housing chamber of the mating connector L1 first HV contact of plug and mating plug L2 second HV contact of plug and mating plug L3 third HV contact of plug and mating plug N Neutral conductor contact of plug and mating plug

Claims

[1] Plug-in system (100) for securely plugging a plug (101) into a mating plug (102), the plug-in system (100) comprising: a mating connector (102); a plug (101) which can be plugged into the mating plug (102); a locking element (110) which, when the plug (101) is plugged into the mating plug (102), is movable from a first locking position (111) into a second locking position (112), wherein the locking element (110) in the second locking position (112) locks the plug (101) plugged into the mating plug (102); and a safety circuit (120) which is open in the first locking position (111) and closed in the second locking position (112) to indicate the locking of the plug (101) plugged into the mating plug (102). [2] Plug-in system (100) according to claim 1, wherein the locking element (110) can only be moved from the first locking position (111) into the second locking position (112) when the plug (101) has been plugged into the mating plug (102); and wherein the safety circuit (120) only closes when the locking element (110) has been moved from the first locking position (111) into the second locking position (112). [3] Plug system (100) according to claim 1 or 2, wherein the locking element (110) and / or the safety circuit (120) is designed to provide a plug position securing (CPA) for securing a locking of the plug (101) on the mating plug (102). [4] Plug-in system (100) according to one of the preceding claims, wherein the mating connector (102) comprises a mating connector housing (103) and the connector (101) comprises a connector housing (104); wherein the safety circuit (120) is arranged outside the mating connector housing (103) and outside the connector housing (104). [5] Plug-in system (100) according to one of the preceding claims, wherein the safety circuit (120) comprises a first contact element (122) and a second contact element (121); wherein the first contact element (122) establishes an electrical connection with the second contact element (121) when the safety circuit (120) is closed. [6] Plug-in system (100) according to claim 5, wherein one of the two contact elements (122, 121) is mounted in or on the locking element (110). [7] Plug-in system (100) according to claim 6, wherein the second of the two contact elements (122, 121) is mounted in or on the mating connector (102). [8] Plug-in system (100) according to one of claims 5 to 7, wherein the second contact element (121) is arranged in a housing chamber (123) of the mating connector (102); and wherein the first contact element (122) is arranged in a housing chamber (116) in a dome (117) of the locking element (110). [9] Plug-in system (100) according to claim 8, wherein the dome (117) moves into the housing chamber (123) of the mating connector (102) when the locking element (110) is moved from the first locking position (111) to the second locking position (112) in order to establish the electrical connection of the first contact element (122) to the second contact element (121). [10] Plug-in system (100) according to claim 9, wherein the locking element (110) comprises a seal (115) which is arranged on the dome (117) and which, when the dome (117) is retracted into the housing chamber (123) of the mating connector (102), comes into contact with the housing chamber (123) and seals the electrical connection of the first contact element (122) to the second contact element (121) against environmental influences outside the housing chamber (123).

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