Power distributor and motor vehicle with such a power distributor

Abstract

A power distributor (10) of a high-voltage electrical system of a motor vehicle, comprising at least two functional modules (11, 12), each comprising a housing (13) and at least one connecting element (20) arranged in the housing (13), wherein the connecting element (20) comprises a plug section (21) protruding from the housing (13) and a socket section (22) accessible from outside the housing (13), and wherein the functional modules (11, 12) are mechanically and electrically connectable by inserting the plug section (21) of a first functional module (11) into the socket section (22) of a second functional module (12).

Description

The invention relates to a power distributor, in particular for electric high-voltage systems in motor vehicles, and to a motor vehicle, in particular a multi-track commercial vehicle, having such a power distributor.Prior ArtFor distributing electric current in motor vehicles, in particular in high-voltage applications, distribution boxes are usually provided. Such a distribution box, also called a power distribution unit (PDU), is often specially adapted for the respective motor vehicle in order to be able to utilize the available installation space in the motor vehicle. As a result, many different junction boxes must be developed and manufactured, which results in high cost.Although it is already known to construct such power distribution boxes in modular fashion. The individual modules are connected, however, via a connecting element which in turn has to be adapted to the number and function of the modules to be connected.CN 101 895 073 B describes, for example, a modular distribution box, wherein eight individual modules are coupled to one another via a common connecting module. For application purposes in which less than eight modules are used, additional installation space is taken up by the connecting module, which can otherwise be saved. In applications in which more than eight, in particular no multiple of eight, modules are used, a specially adapted connection module is required.A modular power distributor is known from DE 10 2015 221 899 B3. The power distributor has a first controller and a plurality of connection modules connected thereto for mounting on a mounting rail. Each connection module has lateral coupling contacts for electrical and / or signal connection to at least one further connection module. The connection modules can thus be arranged in series.Furthermore, a modular plug-in system is known from DE 20 2012 104 446 U1. The modular plug system is used for power distribution and use in the household. It has a plurality of modules which can be inserted into one another and which can be connected to one another in such a way that they can be rotatably released relative to one another about an axis of rotation.Against this background, the object of the invention is to specify a power distributor, in particular for electrical high-voltage systems in motor vehicles, which enables standardization of the production and at the same time can be adapted to different vehicle concepts in a modular and installation space-optimized manner. It is a further object of the invention to specify a motor vehicle having such a power distributor.SUMMARY OF THE INVENTIONThe object is achieved with a power distributor according to claim 1 and a motor vehicle according to claim 13. Advantageous further developments of the invention are the subject of the dependent claims.The solution according to the invention consists in particular in specifying a power distributor of an electric high-voltage system of a motor vehicle, having at least two functional modules which each have a housing and at least one connecting element which is arranged in the housing. The connector has a plug portion protruding from the housing. Further, the connector includes a socket portion accessible from outside the housing. According to the invention, the functional modules can be connected mechanically and electrically by inserting the plug section of a first functional module into the socket section of a second functional module.The invention thus provides a power distributor which can be composed of individual functional modules, the number of functional modules being arbitrary. In this way, any current distributors of any desired size can be configured via identical functional modules which are of uniform and standardized design. This saves development costs and also facilitates the adaptation of the power distributor to different vehicle types or assemblies.A further advantage is that, as a result of the connection of the plug section to the socket section, two functional modules can be connected to one another not only purely electrically but also mechanically at the same time. Additional connector modules are not required. This increases flexibility in the configuration of power distributors and reduces the diversity of components, which is positively reflected in the production costs.In a preferred embodiment of the invention, it is provided that the socket section has a clamping device for the force-locking, in particular clamping, fixing of the plug section. A clamping device enables a particularly simple and easily mountable mechanical connection between the functional modules. At the same time, the clamping device ensures long-term good electrical contact between two connecting elements of the functional modules.It is particularly preferred if the clamping device is arranged in a side wall of the socket section and is adapted to urge a plug section against a contact surface which is arranged opposite the clamping device. Such a clamping device is suitable for establishing a good mechanical connection between two functional modules, wherein the effort required for plugging the plug section into the socket section is limited. At the same time, a permanently good electrical contacting of the connecting elements with one another is achieved in this way. In particular, wear-caused material shrinkage can be compensated by the clamping device if, in preferred embodiments, the clamping device has a prestress which acts on the plug contact and thus urges it against the contact surface.The clamping device can have at least one ball thrust piece. A ball thrust piece usually comprises a ball or a ball head as contact element to the plug section. The ball thrust piece can be prestressed by a compression spring, so that when the plug section is inserted into the socket section, the ball or the ball head escapes against the spring force of the compression spring and the spring force of the compression spring subsequently ensures that the plug section is forced continuously onto an opposite contact surface. The ball thrust piece thus has a prestress which ensures permanent electrical contact and a mechanical clamping force. In this connection, it can also be provided that the plug section has a corresponding recess in the region on which the ball thrust piece acts for clamping, in which recess the ball or the ball head of the ball thrust piece engages. In this way, an additional form-fitting connection is established between the ball thrust piece and the plug section.The clamping device preferably has at least two, particularly preferably at least 4 ball thrust pieces. The ball thrust pieces can then each be prestressed by a compression spring. Particularly preferably, the ball thrust pieces are arranged distributed on the side wall of the bushing section.In general, it is advantageous if the connecting element is formed by an electrically conductive busbar. The connecting element, in particular the busbar, can be formed integrally, in particular monolithically. The connecting element designed as a busbar thus enables continuous contacting of the functional elements connected to one another. Thus, a plurality of current-carrying lines or cables can be brought together by means of the busbar. The busbar can be used, for example, as a potential compensation busbar.In a further embodiment of the invention, a plurality of functional modules can be stacked and can be connected to one another mechanically and electrically via the connecting elements. By stacking a plurality of functional modules, a power distributor can be configured in almost any desired size. The stackability also brings about a compact construction of the current distributor and enables simple assembly.In order to be able to distribute the electric current flowing via the connecting elements or busbars, it is preferably provided that the connecting elements each have a contact flange which has a thread for receiving a connecting screw. The contacting flange enables the connection of, for example, cable shoes, which can be mechanically fastened to the contacting flange by means of a connecting screw that can be connected to the thread and at the same time electrically contacted. In this way, current-carrying cables can be coupled to the connecting element, for example in order to distribute current conducted via the busbar or the connecting element to individual cables.The functional modules can each have two connecting elements, wherein the connecting elements are separated from one another by an intermediate wall of the housing. In particular, the connecting elements are electrically separated from one another by the intermediate wall of the housing. This increases the possible uses of the current distributor, since in this way two different current-carrying busbars can be provided.In this connection, it should be noted that the housing is preferably formed from an electrically insulating material. In particular, the intermediate wall of the housing can also be formed from an electrically insulating material. Plastics are used in particular as electrically insulating materials. In general, it also applies that it is preferred if the housing is formed integrally from a plastic material.It is furthermore advantageous if the housing and the connecting elements are formed or arranged symmetrically, wherein the intermediate wall forms a plane of symmetry. This has the advantage that, on the one hand, a higher number of identical parts can be used, which reduces the production costs. At the same time, the functional modules can also be arranged rotated through 180 degrees relative to one another and connected to one another. This increases the flexibility for configuring a power distributor. In particular, individual outgoing cables of the power distributor can thus be arranged offset by 180°. For example, the cables of a first functional module can be led out of the housing in a first direction, whereas the cables of a second functional module lead away in an opposite direction. Alternatively, the cables of an individual functional module can also be guided out of its housing in different, opposite directions. This flexibility makes it possible to adapt the power distributor individually to different installation situations, wherein cost-effective production and assembly is achieved on account of the high level of direct component. By discharging the cables in different directions from the housing of the power distributor, it is also avoided that the outgoing cables become entangled in one another.The intermediate wall may also have a cylindrical channel adapted to receive a screw connection. The screw connection can fix the plug connection formed by means of the connecting elements of two functional elements. In other words, the housings of the power distributors can be connected by an additional screw connection. This prevents the plug connection between two functional elements from being unintentionally released.In the present invention, it is provided in a particularly preferred embodiment that the connecting element is designed for an electrical voltage of at least 60 volts, in particular at least 100 volts, in particular at least 150 volts, in particular at least 400 volts, in particular at least 800 volts, in particular at least 1250 volts. The power distributor described here is therefore suitable in particular for high-voltage applications, preferably in motor vehicles. In high-voltage applications, the electrical voltage is typically at most 2000 volts. At electrical voltages above 36 kilovolt, one speaks of high-voltage applications.An independent aspect relates to a motor vehicle, in particular a multi-track utility vehicle, having a power distributor described above. In particular in the case of commercial vehicles, there is a lack of installation space, so that a modular concept of a power distributor can be used well in various types and assemblies of commercial vehicles.Brief Description of the DrawingsFurther features, advantages and embodiments of the invention are evident from the following description of embodiments of the power distributor with reference to the figures. The following are shown: FIG. 1 shows a perspective sectional illustration of a current distributor according to the invention according to a preferred exemplary embodiment; FIG. 2 shows a further perspective sectional illustration of the current distributor according to FIG. 1 ; and FIG. 3 shows a perspective illustration of a power distributor according to the invention with cables connected thereto.WAYS OF CARRYING OUT THE INVENTIONFIG. 1 shows a perspective view of a longitudinal section through a power distributor 10 according to the invention, which is formed from a plurality of functional modules 11, 12. Each functional module 11, 12 comprises a housing 13 in which at least one connecting element 20 is arranged. In the exemplary embodiment according to the appended drawings, two connecting elements 20 are provided in each case in a housing 13 of a functional module 11, 12.The housing 13 of the functional module 11, 12 comprises a housing base 15 and the housing walls 14, which are arranged substantially perpendicularly on the housing base 15. Furthermore, an intermediate wall 17 is provided which divides the housing 13 into two housing parts, wherein the housing parts are arranged and equipped in mirror-image or symmetrical manner. The intermediate wall 17 thus forms a plane of symmetry for the housing 13.In the intermediate wall 17 there is also formed a cylindrical channel 18. The cylindrical channel 18 has a through opening. The channels 18 of two functional modules 11, 12 which are connected to one another are preferably aligned with one another, so that the housings 13 of two adjacent functional modules 11, 12 can be screwed together via the channels 18.In the housing base 15, in each housing part, a housing opening 16 is provided, through which a plug section 21 of the connecting element 20 extends. The plug portion 21 thus protrudes beyond the housing 13. In the embodiment shown here, the plug section 21 is substantially designed as a rectangular plug blade which has at its tip at least two, preferably four, centering bevels 23. The centering bevels 23 form a taper of the tip of the plug section 21, so that insertion into a socket section 22 of an adjacent connecting element 20 is facilitated.The connector 20 generally includes a socket portion 22 adjacent the plug portion 21, and the socket portion 22 is disposed entirely within the housing 13. Each socket portion 22 includes a recess which preferably simulates the shape of the plug portion 21. In the exemplary embodiment shown here, the recess is bounded in cross section by side walls 26 which project from a base 27 of the socket section 22.A contacting flange 32 extends from one of the side walls 26 and extends substantially parallel to the housing base 15. The contact flange 32 has a thread 33 into which a connecting screw 37 can be screwed. By means of the connecting screw 37, a cable lug 34 of a cable 36 can be coupled to the connecting element 20 (FIG. 2 ), for example.The connecting elements 20 are preferably formed in one piece or monolithically. In particular, the connecting elements 20 of the functional modules 11, 12 each form a busbar. The connecting elements 20 comprise the plug section 21, the socket section 22 and the contacting flange 32.It is preferably provided that the functional modules 11, 12 are each of identical design and can be connected to one another in modular fashion. In this way, power distributors 10 having a multiplicity of identical functional modules 11, 12 can be provided, it being possible for the power distributor 10 to be custom-made in an application-specific manner. Thus, for example, power distributors 10 having two functional modules 11, 12 or power distributors 10 having three or more functional modules 11, 12 can be produced. In the exemplary embodiment according to FIG. 1, for example, four functional modules 11, 12 are combined to form a power distributor 10.The connecting elements 20 of the functional modules 11, 12 further comprise a clamping device 30, which is located in the socket section 22. The clamping device 30 is formed in a side wall 26 of the socket section 22. The side wall 26 opposite the side wall 26 which carries the clamping device 30 forms a contact surface 25. the plug section 21 of a connecting element 20 of a first functional module 11 can be urged in this way by the clamping device 30 against the contact surface 25 of the socket section 22 of a connecting element 20 of a second functional module 12. A good mechanical and also electrical connection is thus ensured.In the embodiment shown in the drawings, the clamping device 30 is formed by a plurality of ball thrust pieces 31. Specifically, a plurality of ball pressing pieces 31 are provided in one of the side walls 26 of the connecting member 20. The ball thrust pieces 31 each comprise a ball or ball head 38 and are preferably spring-biased. In the rest state, the ball or the ball head of the ball thrust piece 31 projects somewhat into the socket recess of the socket section 22 or therefore protrudes beyond the side wall 26.When the plug section 21 of a first functional element 11 is inserted, the centering chamfer 23 of the plug section 21 causes the ball thrust piece 31 to be pushed back against the spring force. The ball thrust piece 31 is displaced in such a way that the ball or the ball head 38 is forced back into the side wall 26. The spring force acting on the ball pressing piece 31 then urges the plug portion 21 of the first functional module 11 to the contact surface 25 of the socket portion 22 of the second functional module 12, and thus the plug portion 21 is clamped in the socket portion 22.In order to facilitate the insertion of the plug section 21 into the socket section 22, the socket section 22 has mouth bevels 24 in each case on the upper edge of its side walls 26. The mouth bevels 24 essentially form a taper in the direction of the bottom 27 of the bushing section 22.It can be clearly seen in FIG. 2 how a current distributor 10 can be constructed from two functional modules 11, 12. The electric current flowing via the connecting elements 20 designed as a busbar is preferably distributed via cable lugs 34 on cable 36. The connecting screw 37 extends through the cable lug 34 and thus fixes the latter on the contact flange 32.In the perspective illustration of the power distributor 10 according to FIG. 3, it can be seen that housing 13 of each functional module 11, 12 has a cable feedthrough 35. The cable feedthrough 35 is formed in particular in a housing wall 14 of the housing 13. The cable feedthrough 35 is configured in the usual manner as a moisture-proof cable feedthrough 35. Cables 36 each run through the cable feedthrough 35, ending in cable blocks 34, which are connected to the contacting flanges 32 according to the illustration in FIG. 2.To mount a power distributor 10, a plurality of functional modules 11, 12, which are preferably of identical design, are firstly plug-connected to one another via the connecting elements 20. The plug connection is effected by inserting the plug sections 21 of a first functional module 11 into the socket sections 22 of a second functional module 12. In order to prevent this plug connection from becoming detached from one another again, screws or threaded rods can additionally be guided through the channels 18 of the intermediate walls 17 of the housings 13 of the functional modules 11, 12 which are aligned with one another, in order thus to connect the functional modules 11, 12 to one another in a fixing manner.The power distributors 10 described here are suitable in particular for use as power distributors in motor vehicles, in particular in high-voltage on-board power supply systems. In the context of the present application, high-voltage applications are applications in which electrical voltages of more than 60 volts, in particular more than 100 volts, in particular more than 150 volts, in particular at least 400 volts, preferably at least 800 volts, occur. Electrical voltages of more than 1200 volts, in particular at least 1250 volts, can also be used in high-voltage systems. The modular construction of the power distributor 10 can be used in particular expediently in commercial vehicles in which sufficient installation space is usually available to accommodate power distributors 10 of different sizes. Depending on the function and objective of the respective commercial vehicle, different power distributors 10 can thus be formed from identical functional modules 11, 12.List of reference characters10 Power distributor 11 First functional module 12 Second functional module 13 Housing 14 Housing wall 15 Housing base 16 Housing opening 17 Intermediate wall 18 Channel 20 Connecting element / busbar 21 Plug section 22 Socket section 23 Centring chamfer 24 Opening chamfer 25 Contact surface 26 Side wall 27 Base 30 Clamping device 31 Ball thrust piece 32 Contact flange 33 Thread 34 Cable lug 35 Cable lead-through 36 Cable 37 Connecting screw 38 Ball head

Claims

Power distributor (10) of an electric high-voltage system of a motor vehicle, having at least two functional modules (11, 12) which each have a housing (13) and at least one connecting element (20) which is arranged in the housing (13), wherein the connecting element (20) has a plug section (21) which protrudes from the housing (13) and a socket section (22) which is accessible from outside the housing (13), and wherein the functional modules (11, 12) can be connected mechanically and electrically by inserting the plug section (21) of a first functional module (11) into the socket section (22) of a second functional module (12).Power distributor (10) according to Claim 1da characterized in that the socket section (22) has a clamping device (30) for fixing the plug section (21) in a force-fitting, in particular clamping, manner.Power distributor (10) according to claim 2 characterised in that the clamping device (30) is arranged in a side wall (26) of the socket section (22) and is adapted to urge a plug section (21) against a contact surface (25) arranged opposite the clamping device (30).Power distributor (10) according to Claim 2 or 3, characterized in that the clamping device (30) has at least one ball thrust piece (31).Power distributor (10) according to one of the preceding claims, characterized in that the connecting element (20) is formed by an electrically conductive busbar.Power distributor (10) according to one of the preceding claims, characterized in that the connecting element (20) is formed in one piece, in particular monolithically.Power distributor (10) according to one of the preceding claims, characterized in that a plurality of functional modules (11, 12) can be stacked and can be connected to one another mechanically and electrically via the connecting elements (20).Power distributor (10) according to one of the preceding claims, characterized in that the connecting element (20) has a contact flange (32) which has a thread (33) for receiving a connecting screw.Power distributor (10) according to one of the preceding claims, characterized in that the functional modules (11, 12) each have two connecting elements (20), wherein the connecting elements (20) are separated from one another by an intermediate wall (17) of the housing (13).Power distributor (10) according to Claim 9da characterized in that the housing (13) and the connecting elements (20) are of symmetrical design or are arranged, the intermediate wall (17) forming a plane of symmetry.Power distributor (10) according to Claim 9 or 10da characterized in that the intermediate wall (17) has a cylindrical channel (18) which is adapted to receive a screw connection which fixes the plug connection, formed by means of the connecting elements (20), of two functional elements (11, 12).Power distributor (10) according to one of the preceding claims, characterized in that the connecting element (20) is designed for an electrical voltage of at least 60 volts, in particular at least 100 volts, in particular at least 150 volts.Motor vehicle, in particular multi-track commercial vehicle, having a power distributor (10) according to one of the preceding claims.

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