Fast charging station for electric vehicles

Abstract

The invention relates to a fast charging station for electric vehicles with at least one power module (2), wherein the power module (2) comprises power electronics, in particular a current transformer, and wherein the power module (2) is mounted in a mounted position in the fast charging station (1) via a mounting arrangement (3). It is proposed that the mounting arrangement (3) has a pivot bearing (9) by means of which the power module (2) is pivotably mounted, so that the power module (2) can be pivoted between the mounted position and a maintenance position.

Description

[0001] The present invention relates to a fast charging station for electric vehicles according to the preamble of claim 1 and to a method for maintaining a fast charging station according to claim 11.

[0002] Fast charging stations, also known as high-performance chargers, are direct current charging stations for electric vehicles, especially automobiles, but also trucks, ships and the like.

[0003] In addition to the purchase price, maintenance costs, partly comprised of expenses for maintenance technicians, represent a significant portion of the overall cost of a fast charging station. Furthermore, well-known fast charging stations, especially those exceeding 150 kW, require considerable space around them to ensure unobstructed access for maintenance. This space must be kept clear, meaning that a typical fast charging station cannot, for example, be placed against a wall.

[0004] A well-known fast charging station (Alpitronic Hypercharger) features power modules mounted on rails. These rails allow the power modules to be moved out of the charging station from a mounted position to a maintenance position. The rails must be very robust and durable to ensure reliable and stable movement.

[0005] The challenge lies in achieving a stable and cost-effective mounting of the power modules.

[0006] The invention is based on the problem of designing and further developing the known fast charging station in such a way that a more stable and / or cost-effective mounting of the power modules is provided.

[0007] The above problem is solved by the features of the characterizing part of claim 1.

[0008] The fundamental consideration is that the power modules can be mounted in a pivoting manner. A pivot bearing is stable; the power module corrects its position within a certain range and essentially "falls" into its mounted position. A pivot bearing is less prone to tilting than a linear guide. Furthermore, creating and removing the pivot bearing for inserting or removing the power module is simpler than with two linear rails. Additionally, after pivoting, one side of the power module is easily locked, eliminating a step compared to a linear guide where the power module is locked at both the top and bottom.

[0009] Specifically, it is proposed that the mounting arrangement has a pivot bearing via which the power module is pivotably mounted, so that the power module can be pivoted between the mounted position and a maintenance position.

[0010] The mounted position is the fully functional position that the power module regularly assumes during charging operation of the charging station.

[0011] According to claim 2, the power module can only be removed from the fast charging station when it is in the maintenance position. A predefined workflow increases safety and prevents the power module from falling out of the fast charging station uncontrollably. Additionally, a swivel lock can be provided.

[0012] Claim 3 describes preferred embodiments of the pivot bearing. A hook-shaped counter-bearing element on the power module secures the pivot bearing in the mounted position against removal of the power module without the need for any additional elements. Pivoting the bearing automatically releases the locking mechanism.

[0013] In an embodiment according to claim 4, the fast charging station has a module base by which the power module can be supported on the floor in the maintenance position. This ensures the power module remains stable in the maintenance position in a simple manner. The module base can be removable and stored in the fast charging station as standard. In particular, only one module base is required for all power modules, thus requiring less storage space. The module base can also be telescopic, further reducing the storage space required in the fast charging station.

[0014] According to claim 5, module handles are provided which can also be detached and stored in the fast charging station. These handles allow the power module to be lifted out of the fast charging station in the maintenance position.

[0015] Claims 6 to 8 relate to preferred embodiments that result in a fast charging station requiring particularly little space for maintenance access. In particular, it is possible to position the fast charging station with its back against a wall or the like. Parking spaces can be provided next to the fast charging station, and maintenance access is preferably located only at the front.

[0016] Claim 9 relates to an embodiment in which the power module automatically makes contact with one or more electrical terminals when pivoted into the mounted position. This is particularly feasible with a pivot bearing, as precise positioning is possible and the power module can be locked into place. Furthermore, the power module reliably reaches its end position during a pivoting movement after the tipping point has been passed.

[0017] Claim 10 concerns preferred performance classes of the fast charging station. The larger the station, the more important its space requirements become.

[0018] According to a further teaching according to claim 11, which has independent significance, a method for maintaining a proposed fast charging station is claimed, wherein a power module is pivoted out of the fast charging station, preferably wherein the module handle and / or the module foot are connected to one of the power modules.

[0019] Reference may be made to all statements regarding the proposed fast charging station.

[0020] The invention will now be explained in more detail with reference to a drawing that merely illustrates exemplary embodiments. The drawing shows Fig. 1. A proposed fast charging station from the outside, Fig. 2 the fast charging station in the open state, Fig. 3. the swiveling of a power module with the module base mounted and Fig. 4 A detailed view of the swivel bearing during swiveling.

[0021] The embodiment shown in the figures, which is preferred in this respect, relates to a fast charging station 1 for electric vehicles with at least one power module 2, wherein the power module 2 comprises power electronics, in particular a current transformer. The power module 2 is mounted in a fixed position in the fast charging station 1 by means of a mounting arrangement 3. Fig. Figure 2 shows this assembled position. Fig. 2. When fast charging station 1 is open, and when power module 2 is in use, it is always in the mounted position.

[0022] Fig. Figure 1 shows an external view of a proposed fast charging station 1 for electric vehicles. This station has at least one connection point 4 for an electric vehicle, in this case a permanently attached charging cable 5. Preferably, the fast charging station 1 has at least, and in this case exactly, two connection points 4. A fast charging station 1 is used to charge an electric vehicle using direct current and a power output of usually at least 50 kW. The fast charging station 1 is typically connected to an alternating current network for this purpose.

[0023] As seen in the open view in Fig. As can be seen from Figure 2, the fast charging station 1 has at least one individually controllable power module 2. Here, the fast charging station 1 has seven power modules 2, each of which provides a portion of the total power of the fast charging station 1, for example, 30 kW each. The power modules 2 can be flexibly distributed among the connection points 4.

[0024] The term "individually manageable" is to be understood broadly here. For example, power module 2 weighs approximately 39 kg and is therefore not easily handled. However, it can be removed individually, and the components of power module 2 are not individually installed in the fast charging station 1. Preferably, the weight of a power module 2 is at least 20 kg, and more preferably at least 30 kg.

[0025] We will first consider only one power module 2; all statements regarding this power module 2 can apply accordingly to further power modules 2. The power module 2 comprises power electronics. The power electronics include a power converter arrangement. Here, and preferably, the power converter arrangement serves to convert a three-phase mains voltage as the input voltage of the fast charging station 1 into a DC voltage. Here, and preferably, the power electronics include a rectifier and a downstream DC-DC converter, which are not shown. DC bus bars 6 for distributing the output power of the power modules 2 to the connection points 4 are visible in the upper area of ​​the fast charging station 1. The AC voltage input is located in the lower area and is not shown. The fast charging station 1 has a station housing 7 in which the power module 2, here the power modules 2, are arranged.The power module 2 also has a housing 8.

[0026] It is essential that the fastening arrangement 3 has a pivot bearing 9, via which the power module 2 is pivotably mounted, so that the power module 2 can be pivoted between the mounted position and a maintenance position. Fig. Figure 3 shows the swiveling process. In the horizontal position, the power module 2 is in the maintenance position; in the vertical position, it is in the mounted position.

[0027] The fast charging station 1 preferably has a receptacle 10 for the power module 2, in which the power module 2 is held in its mounted position. The receptacle 10 surrounds the power module 2 in at least four, preferably five, orthogonal spatial directions. This assumes a total of six orthogonal spatial directions, i.e., the three dimensions of an orthogonal base in two directions each. The power module 2 can be pivoted out of the receptacle 10. Here, and preferably, the fast charging station 1 has several individually pivotable power modules 2.

[0028] As in Fig. 3 The power module 2 is recognizable here and preferably pivotable over its shortest edge.

[0029] Here, and preferably, the power module 2 must first be pivoted into the maintenance position in its mounted position before the power module 2 can be detached from the mounting arrangement 3 and removed from the fast charging station 1.

[0030] Additionally or alternatively, the mounting arrangement has 3 releasable fastening elements, in particular pins, with which the power module 2 is secured against pivoting in the mounted position. The fastening elements connect the power module 2 here, and preferably, to the receptacle 10.

[0031] Fig. Figure 4 shows a detailed view of the pivot bearing 9. It can be seen that the pivot bearing 9 may have a bearing element 11 and that the power module 2 preferably has a housing 8 on which a counter bearing element 12 is arranged. The counter bearing element 12 is then intended to cooperate with the bearing element 11 to provide the pivot bearing 9. It can be seen that the power module 2 can be moved from its mounted position in Fig. 4b) can only be moved by pivoting. Only in the maintenance position in Fig. 4d) The bearing element 11 and the counter bearing element 12 can be separated from each other, whereby the pivot bearing 9 is disassembled and the power module 2 can be removed upwards.

[0032] Here, and preferably, the power module 2 is linearly displaced during pivoting or following pivoting, thereby unlocking the pivot bearing 9 so that the power module 2 can be removed. Fig. Figure 4d) shows the state after the relocation. Preferably, the bearing element 11 is a horizontally oriented pin and the counter bearing element 12 is hook-shaped and engages the pin in the assembled position.

[0033] Here, and preferably, the counter bearing element 12 surrounds the bearing element 11 during a pivoting of the power module 2. In the mounted position, the counter bearing element 12 is preferably decoupled from the bearing element 11 in at least one direction, in particular the vertical direction. Fig. 4a) A slight play is evident between the bearing element 11 and the counter-bearing element 12. Here, and preferably, the power module 2 rests in the mounted position on a component of the fast charging station 1, specifically on a base of the receptacle 10. This decoupling between the bearing element 11 and the counter-bearing element 12 prevents the power module 2 from unintentionally pivoting back. Here, and preferably, the receptacle 10 has plastic skids on which the power module 2 rests in the mounted position.

[0034] It can therefore be stated in general terms that the pivot bearing 9 is decoupled here, and preferably in the mounted position. A pivoting of the power module 2 therefore begins here, and preferably, with an adjustment, in particular a pivoting over an edge, of the power module 2, which causes the pivot bearing 9 to engage.

[0035] To secure the power module 2 in its mounted position, the fast charging station 1 may be provided with a module base 13, which is particularly telescopic. In the maintenance position, the module base 13 supports the power module 2 on the ground. The module base 13 is attached to the power module 2, preferably in a pivotable manner. Preferably, the module base 13 can be connected to and / or detached from the power module 2, particularly without tools via a snap-fit ​​connection. Most preferably, the module base 13 is stored inside the fast charging station 1 when not in use. This eliminates the need for a maintenance technician to bring the module base 1, and it is not necessary to have one module base 13 per power module 2. Instead, the module base 13 is attached in a dedicated storage position, here and preferably at a maintenance hatch 14, of the fast charging station 1 and is used as needed on the power module 2 that is to be serviced.

[0036] In the maintenance position, the power module 2 rests here, preferably on the module base 13 and the swivel bearing 9 ( Fig. 3).

[0037] Furthermore, it is preferably provided that the fast charging station 1 has at least one, preferably two, module handles 15 and that the module handle 15 or the module handles 15 are detachably connectable and / or detachable to the power module 2, in particular without tools via a snap-fit ​​connection. The module handle 15 or the module handles 15 are also preferably attached in a storage position of the fast charging station 1, in particular at the maintenance hatch 14.

[0038] Preferably, the module handles 15 can be attached to the power module 2 in the maintenance position, particularly to a side of the power module 2 located at the top in the maintenance position, such that the power module 2 can be detached from the mounting arrangement 3 by means of the module handles 15. The module handle 15 or handles 15 are also preferably used on one of the power modules 2 as needed. It is therefore generally preferred that the fast charging station 1 has exactly one module foot 13 and / or exactly two module handles 15.

[0039] With regard to the general maintenance concept of the fast charging station 1, it is preferably the case that the fast charging station 1 has a station housing 7 and that the station housing 7, in particular, has a maintenance access 16, in particular a maintenance hatch 14. This maintenance hatch 14, here designed as a maintenance door, is the front side wall 17 of the fast charging station 1. Fig. 1, which is in Fig. 2 hidden and in Fig. 3 is indicated as open. This can be accessed via the one also in Fig. 1 indicated door handle 18 can be opened and preferably has a lock.

[0040] Here, and preferably, a payment terminal 19 and / or a display 20 and / or at least one connector 21 and / or an electricity meter 22 and / or control electronics are arranged at the maintenance hatch 14 and are accessible when the maintenance hatch 14 is open. "Accessible" in this context means accessible for maintenance purposes. The display 20, the payment terminal 19, and the connector 21 are also accessible from the outside, but usually cannot be serviced from there. Here, they are integrated into the maintenance hatch 14 and can be serviced from the rear when the maintenance hatch 14 is open. The meter here, and preferably, also has an externally readable display 20 and is connected via a data connection, here fiber optic, to a shunt inside the fast charging station 1 on the DC bus bars 6. Here, and preferably, one electricity meter 22 is provided per connection point 4, i.e., two.The control electronics are attached here, preferably on the inside of the maintenance hatch 14. Various components of the fast charging station 1 are accessible here, preferably, without removing any protective covering, particularly due to their arrangement on the maintenance hatch 14. Opening the maintenance hatch 14, preferably via a contact switch for the hatch 14, results in the fast charging station 1 being switched off. The AC input rails can be covered by a protective covering.

[0041] Here, and preferably, all charging cables 5 of the fast charging station 1 are arranged on different walls of the station housing 7 than the maintenance hatch 14, here on the right and left side wall 17 in Fig. 1.

[0042] Furthermore, it is preferably provided here that an opening released by the maintenance hatch 14 (in Fig. 2 and Fig. 3 open) the power modules 2 are pivotable. The opening released by the maintenance hatch 14 also provides access to fuses, in particular all fuses, of the fast charging station 1 and / or a socket, in particular a Schuko socket, and / or DC busbars 6 and / or input rails and / or a mains connection and / or a dust filter 23. Here, and preferably, all electrical and electronic components and / or all components of the fast charging station 1 requiring maintenance are accessible via the maintenance hatch 14.

[0043] Preferably, the fast charging station 1 has four side walls 17, charging cables 5 are attached to two opposite side walls 17, a maintenance hatch 14 is arranged on one of the side walls 17, and no functional unit of the fast charging station 1 is arranged on the fourth side wall 17, so that access to the fourth side wall 17 is not necessary during normal operation or for maintenance of electrical and electronic components of the fast charging station 1. Preferably, the fast charging station 1 is essentially cuboid in shape with exactly four side walls 17. Fig. Figure 3 indicates on the floor that the space required for maintenance purposes is quite small.

[0044] It is also provided and preferred that the power module 2 has a DC connection, that the DC connection is automatically connected to a DC distribution, in particular a DC bus 6, of the fast charging station 1 by pivoting the power module 2 from the maintenance position to the mounted position, and / or that the power module 2 has an AC connection, that the AC connection is automatically connected to an AC distribution, in particular an AC bus, of the fast charging station 1 by pivoting the power module 2 from the maintenance position to the mounted position. The DC connection and / or the AC connection can be a plug or a socket, which is otherwise connected to a corresponding counterpart on the fast charging station 1. Alternative contact options are conceivable.Either way, contact can be established simply by pivoting the device or subsequently secured by a maintenance technician, for example by attaching a clamp to two rails that are brought into contact by the pivoting action. The DC and / or AC connection can be spring-loaded and / or meet a spring-loaded counterpart to compensate for any play and ensure reliable contact.

[0045] Furthermore, it is preferably provided that the fast charging station 1 has at least 3, preferably at least 4, and more preferably at least 5 power modules 2, which together provide at least 150 kW, preferably at least 175 kW, and more preferably at least 200 kW of power.

[0046] According to a further teaching, a method for maintaining a proposed fast charging station 1 is proposed, wherein a power module 2 is pivoted out of the fast charging station 1, preferably, wherein the module handle 15 and / or the module foot 13 are connected to one of the power modules 2.

[0047] Reference may be made to all statements regarding the proposed fast charging station 1.

Claims

[1] Fast charging station for electric vehicles with at least one power module (2), wherein the power module (2) has power electronics, in particular a current transformer, wherein the power module (2) is fastened in a mounted position via a fastening arrangement (3) in the fast charging station (1), characterized by that the fastening arrangement (3) has a pivot bearing (9) via which the power module (2) is pivotally mounted, so that the power module (2) can be pivoted between the mounted position and a maintenance position. [2] Fast charging station according to claim 1, characterized bythat the power module (2) in the mounted position must first be pivoted into the maintenance position before the power module (2) can be released from the fastening arrangement (3) and removed from the rapid charging station (1), and / or that the fastening arrangement (3) has releasable fastening elements, in particular pins, with which the power module (2) is secured against pivoting in the mounted position. [3] Fast charging station according to claim 1 or 2, characterized bythat the pivot bearing (9) has a bearing element (11), that the power module (2) has a housing (8), that a counter-bearing element (12) is arranged on the housing (8), that the counter-bearing element (12) cooperates with the bearing element (11) to provide the pivot bearing (9), preferably that the bearing element (11) is a horizontally aligned pin, that the counter-bearing element (12) is hook-shaped and engages around the pin in the mounted position. [4] Fast charging station according to one of the preceding claims, characterized bythat the rapid charging station (1) has a, in particular telescopic, module base (13), that the module base (13) supports the power module (2) on the ground in the maintenance position, preferably that the module base (13) can be detachably connected to the power module (2), in particular without tools via a snap-in connection, and / or that the power module (2) rests on the module base (13) and the pivot bearing (9) in the maintenance position. [5] Fast charging station according to one of the preceding claims, characterized bythat the rapid charging station (1) has at least one, preferably two, module handles (15), that the module handle (15) or the module handles (15) can be connected to the power module (2) in a detachable manner, in particular without tools via a snap-in connection, preferably that the module handles (15) can be fastened to the power module (2) in the maintenance position, in particular to a side of the power module (2) which is at the top in the maintenance position, in such a way that the power module (2) can be detached from the fastening arrangement (3) at the module handles (15). [6] Fast charging station according to one of the preceding claims, characterized bythat the rapid charging station (1) has a station housing (7), that the station housing (7), in particular precisely, has a maintenance access (16), in particular a maintenance flap (14), preferably that a payment terminal (19) and / or a display (20) and / or at least one plug receptacle (21) and / or an electricity meter (22) and / or control electronics are arranged on the maintenance flap (14) and are accessible when the maintenance flap (14) is open, and / or that all charging cables (5) of the rapid charging station (1) are arranged on different walls of the station housing (7) than the maintenance flap (14). [7] Fast charging station according to claim 6, characterized bythat the power modules (2) can be pivoted through an opening released by the maintenance flap (14), preferably that fuses, in particular all fuses, of the rapid charging station (1) and / or a socket, in particular a Schuko socket, and / or DC rails (6) and / or AC rails and / or a mains connection and / or a dust filter (23) are accessible through the opening released by the maintenance flap (14). [8] Fast charging station according to claim 6 or 7, characterized bythat the rapid charging station (1) has four side walls (17), that charging cables (5) are attached to two opposite side walls (17), that the maintenance flap (14) is arranged on one of the side walls (17), that no functional unit of the rapid charging station (1) is arranged on the fourth side wall (17), so that access to the fourth side wall (17) is not necessary during any normal operation and for maintenance purposes of electrical and electronic components of the rapid charging station (1), preferably that the rapid charging station (1) is designed essentially cuboidally with exactly four side walls (17). [9] Fast charging station according to one of the preceding claims, characterized bythat the power module (2) has a direct current connection, that the direct current connection is automatically contacted with a direct current distribution, in particular a direct current rail (6), of the rapid charging station (1) by pivoting the power module (2) from the maintenance position into the mounted position, and / or that the power module (2) has an alternating current connection, that the alternating current connection is automatically contacted with an alternating current distribution, in particular an alternating current rail, of the rapid charging station (1) by pivoting the power module (2) from the maintenance position into the mounted position. [10] Fast charging station according to one of the preceding claims, characterized by that the rapid charging station (1) has at least 3, preferably at least 4, more preferably at least 5 power modules (2) which together provide at least 150 kW, preferably at least 175 kW, more preferably at least 200 kW of power. [11] Method for servicing a rapid charging station (1) according to one of the preceding claims, wherein a power module (2) is pivoted out of the rapid charging station (1), preferably wherein the module handle (15) and / or the module base (13) are connected to one of the power modules (2).

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