Charging connection unit for an electric vehicle and method for producing an electrical plug connection with a charging connection unit of an electric vehicle

Abstract

Charging connection unit for an electric vehicle, comprising an arrangement of electrical contact elements (13, 13a) for establishing an electrical plug connection with complementary electrical contact elements (14, 14a, 15) of a charging plug (11, 12) to be connected to the charging connection unit (10), a charging flap unit (16) movable between a closed state and an open state to cover the electrical contact elements (13, 13a) of the charging connection unit (10) and to release them for a charging process, characterized by an extendable guide slot (18) for receiving the charging plug (11, 12) in the extended state and then moving back into the charging connection unit (10) together with the received charging plug (11, 12) to establish the electrical plug connection, wherein the guide slot (18) is designed such that it is automatically extended when the loading flap unit (16) is opened.

Description

[0001] The invention relates to a charging connector unit for an electric vehicle. Furthermore, the invention relates to a method for establishing an electrical plug connection with an electric vehicle.

[0002] In particular, the charging connection unit is a charging socket or charging inlet designed for connecting an external charging plug to charge an electrical energy storage device of the electric vehicle. The energy storage device is designed to power the electric vehicle.

[0003] Electrically powered motor vehicles, especially pure electric vehicles or electric vehicles with a hybrid drive, require regular charging of the batteries used to power the vehicle at public or private charging stations. For this purpose, a charging plug, connected to an external electrical power source, for example, via a charging cable, is inserted into a charging connection unit or charging socket provided on the electric vehicle, which is connected to a drive battery or accumulator of the electric vehicle.

[0004] Until now, especially in private vehicles, vehicle users have been required to manually insert the charging plug into the vehicle's charging socket. However, there are also developments that aim to largely or even completely automate the charging process.

[0005] However, plugging in the charging plug is both tactile and sensory. The charging plug must be positioned precisely on the charging socket, and its spatial position must be precisely aligned with the socket's connector face. The weight of the charging plug makes this even more difficult.

[0006] The publication DE 10 2014 107 153 A1 describes a vehicle charging station with a charging device that can be moved between several vehicle parking spaces and has an end effector for electrically coupling to an electric vehicle. The end effector includes a retractable guide to assist in aligning and orienting the end effector with a socket of the electric vehicle.

[0007] The document DE 10 2020 207 394 A1 shows a charging device for electrically powered motor vehicles, consisting of a charging arm with a conductive plug connection, wherein the charging arm comprises spring-elastic means for neutralizing the charging arm and a coupling body spring; a collecting funnel for the charging arm is provided on the electrically powered motor vehicle, wherein the collecting funnel comprises two flaps and a fixed funnel and a guide slot.

[0008] Document US 5,478,249 A describes an electrical connector with a coupling socket that can be connected to an electrical power supply and a socket located in the vehicle that is connected to the accumulator batteries. The coupling socket has lugs for positioning in a corresponding housing.

[0009] The object of the invention is to simplify the plugging process when inserting a charging plug into the charging connection unit of an electric vehicle.

[0010] According to a first aspect of the invention, a charging connection unit for an electric vehicle is provided, comprising an arrangement of electrical contact elements for establishing an electrical plug connection with complementary electrical contact elements of a charging plug to be connected to the charging connection unit, a charging flap unit movable between a closed state and an open state in order to cover the electrical contact elements of the charging connection unit and to release them for a charging process, and an extendable guide slot for receiving the charging plug in the extended state and then moving back into the charging connection unit together with the received charging plug to establish the electrical plug connection, wherein the guide slot is designed in such a way that it is automatically extended when the charging flap unit is opened.

[0011] Preferably, the guide slot comprises a funnel-shaped centering surface which is designed to center the charging plug as it is progressively inserted into the guide slot.

[0012] Preferably, the guide slot comprises at least one further centering surface which is arranged behind the funnel-shaped centering surface in the plug-in direction of the charging plug to be inserted and is aligned parallel to the plug-in direction.

[0013] Preferably, the further centering surface forms a second centering surface which is designed such that it at least partially surrounds a front plug-in area of ​​the charging plug as insertion progresses and contacts it for guidance.

[0014] Advantageously, the further centering surface forms a third centering surface which is formed on both sides of a recess provided in the guide slot and which extends in the plugging direction when the charging plug is inserted and contacts the charging plug on two sides as it is inserted further.

[0015] The guide slot can include the second centering surface and / or the third centering surface. A combination of both is particularly advantageous.

[0016] Preferably, the guide slot can be locked in its retracted position in the charging connection unit.

[0017] Preferably, the guide slot is designed in such a way that it remains in its retracted position when the charging plug is removed.

[0018] Preferably, the charging connection unit comprises a locking element which automatically fixes the guide slot in its extended position and is unlocked by the charging plug when the latter reaches its end position when inserted into the guide slot.

[0019] Advantageously, the locking element is movably mounted in the guide slot.

[0020] Preferably, the locking element is designed in such a way that it is unlocked or can be unlocked by the closing loading flap unit when the guide slot is extended.

[0021] Advantageously, the locking element is designed in such a way that it can be manually unlocked when the guide slot is extended.

[0022] Preferably, the guide slot comprises a plurality of wedge-shaped segments which are arranged in such a way that they surround the received charging plug and are shaped in such a way that they close towards the charging plug as they move into the charging connection unit in order to align and clamp the charging plug.

[0023] According to a second aspect of the invention, a method is provided for the automated production of an electrical plug connection with a charging connection unit of an electric vehicle, comprising the steps of: opening the lockable charging connection unit; extending a guide slot from the charging connection unit and locking the guide slot in its extended position; inserting an external charging plug into the extended guide slot; unlocking and moving the extended guide slot together with the charging plug into the charging connection unit so that it reaches a retracted position in which the electrical plug connection is produced, wherein the guide slot is automatically extended when the charging connection unit is opened.

[0024] Preferably, the guide slot remains in its retracted position when the charging plug is removed from the charging connection unit.

[0025] Preferably, after the charging plug has been removed, the extended guide slot is unlocked by a closing charging flap of the charging connection unit in order to reach its retracted position.

[0026] Advantages, details, and features described in connection with the charging connection unit also apply reciprocally to the specified procedure.

[0027] The term electric vehicle should generally be understood to refer to vehicles that are equipped with a rechargeable power storage unit to power the electric vehicle.

[0028] In the following, exemplary embodiments of the invention are explained in more detail with reference to the drawings, in which: Fig. 1 shows a charging connection unit according to a first preferred embodiment of the invention in a perspective view from the front, together with two different external charging plugs; Fig. 2 which in Fig. 1 shows a sectional view of the charging connection unit with the guide rail extended and locked, together with the different charging plugs; Fig. 3 the charging connection unit with extended and locked guide slot in a similar view, together with an exemplary charging plug at the beginning of a plugging process; Fig. 4 the charging connection unit with the guide slot extended and unlocked in a similar view, together with the charging plug accommodated in the guide slot during the insertion process; Fig. 5 the charging connection unit with the charging plug in a similar view, but after inserting the guide slot; Fig. 6 the charging connection unit according to a variant in a similar view, with the guide slot extended; and Fig. 7 the charging connection unit according to another preferred embodiment of the invention with the guide slot extended, together with a charging plug to be connected, in a perspective view.

[0029] In the figures, identical or corresponding elements are designated by the same reference numerals and, unless expedient, are not described repeatedly. The disclosures contained throughout the description apply mutatis mutandis to identical parts with the same reference numerals or component designations. Furthermore, the positional information chosen in the description, such as top, bottom, side, etc., refers to the directly described and illustrated figure and, in the event of a change in position, is to be applied mutatis mutandis to the new position.

[0030] The Fig. 1 and Fig. 2 show a charging connection unit 10 according to a preferred embodiment of the invention. The charging connection unit 10 is designed as a charging socket or charging inlet for installation in an electric vehicle, wherein it can be fastened in particular to an external body element of the electric vehicle. The charging connection unit 10 serves to connect a charging plug 11 or 12, which is connected to an external electrical charging station, for example, via a charging cable, or can be connected to such a charging station. In this example, the charging connection unit 10 is designed both for connecting a DC charging plug (charging plug 11) and for connecting an AC charging plug (charging plug 12).

[0031] The charging connection unit 10 comprises an arrangement of electrical contact elements 13, 13a for establishing an electrical plug connection with complementary electrical contact elements 14, 14a or 15 of the charging plug 11 or 12 to be connected to the charging connection unit 10.

[0032] Furthermore, the charging connection unit 10 comprises a movable charging flap unit 16, which can be moved back and forth between a closed state and an open state in order to close the charging connection unit 10 to the outside and thereby cover its electrical contact elements 13, 13a, or to open the charging connection unit 10 and thus make its electrical contact elements 13, 13a accessible or release from the outside, so that a charging process can be carried out on the electric vehicle.

[0033] The charging flap unit 16 comprises a hinge arm 16a, which is rotatably mounted in the charging connection unit 10, and at the outer end of which a cover or charging flap 16b (see Fig. 6), is attached.

[0034] The charging connection unit 10 further comprises a movably mounted guide slot 18 which can be extended from the charging connection unit 10 and is designed, in its extended state, to receive the charging plug 11 or 12 before the electrical plug connection is established and then to move back into the charging connection unit 10 together with the received charging plug 11 or 12, so that the electrical plug connection between the charging plug 11 or 12 and the charging connection unit 10 is established.

[0035] The guide slot 18 is designed such that it is automatically extended with or upon opening the charging flap unit 16 or the charging flap 16b. The automatic extension of the guide slot 18 can occur, in particular, during the opening of the charging flap 16b. During extension, the guide slot moves opposite to the insertion direction S of the charging plug 11, 12 into the charging connection unit 10.

[0036] The guide slot 18 is driven, for example, by a spring mechanism, a servo motor or the like, which is coupled, for example, electronically or mechanically to the movement of the loading flap unit 16, for example via a control unit or by a suitable mechanism.

[0037] The guide slot 18 has in its interior for receiving the charging plug 11, 12 a first centering surface 20 which is funnel-shaped and shaped such that it surrounds the charging plug 11 or 12 on at least three sides when it is received in the guide slot 18 and guides and centers it when it is inserted into the guide slot 18.

[0038] In the exemplary embodiment shown here, the first centering surface 20 for guiding and centering the charging plug 11 or 12 is formed on its upper side 22 and on its side surfaces 24 when it is received in the guide slot 10. The upper side 22 and the side surfaces 24 of the respective charging plug 11, 12 to be received therefore also form centering surfaces.

[0039] As in Fig. 2, the first centering surface 20 forms an insertion funnel for the charging plug 11, 12. Due to the funnel-like shape of its centering surface 20, the guide slot 18 has a relatively large inlet opening 21 at its front end, which allows an initially rough or only inaccurate positioning of the charging plug 11 or 12 in the guide slot 18.

[0040] When inserting the charging plug 11 or 12 into the guide slot 18 in the plugging direction S, the outer contour of the charging plug 11 or 12 used in each case is guided in its front region 26 along the guide slot 18 and, due to the centering surface 20 which continuously narrows inwards or backwards, is centered with respect to the contact elements 13 or 13a of the charging connection unit 10.

[0041] The outer contour in the front area 26 of the charging plug 11 or 12 is formed by its upper side 22 and its side surfaces 24 in its front area 26, which is received by the guide slot 18 when inserted into the latter and thus forms a plug-in section.

[0042] The guide slot 18 has on its underside a recess 28 which is open to the front and forms a cutout in the guide slot 18 which is open to the front and is delimited by two opposing second centering surfaces 30 which are formed by side surfaces of the recess and extend in the guide slot 18 in the plug-in direction S (see also Fig. 1). The second centering surfaces 30 each form a side edge of the recess 28.

[0043] The second centering surfaces 30 serve to guide two straight side surfaces 32 of the DC charging plug 11, which also extend in the plugging direction S and are formed between its two contact element regions. Furthermore, the second centering surfaces 30 also serve to guide the front region 26 of the AC charging plug 12 at its underside 34, which is curved outward. The recess 28 is dimensioned such that both the straight side surfaces 32 of the DC charging plug 11 and the curved underside 34 of the AC charging plug 12 are guided between the second centering surfaces 30.

[0044] The recess 28 with its two centering surfaces 30 also forms an insertion funnel for the charging plug 11 or 12. The distance between the opposite second centering surfaces 30 is relatively large at the front end of the guide slot 18, ie at the inlet opening 21, and becomes narrower towards the rear.

[0045] A third centering surface 36 within the guide slot 18, which forms a further centering surface, is arranged behind the funnel-shaped first centering surface 20 in the plugging direction S in order to guide the charging plug 11 or 12 straight on the outer contour of its front region 26 after it has been centered by the first centering surface 20 and by the second centering surfaces 30, so that the electrical contact elements 14, 14a or 15 of the charging plug 11 or 12 and the electrical contact elements 13, 13a of the charging connection unit 10 can be pushed straight and centered into one another.

[0046] A fourth centering surface 38 at the rear or inner end of the guide slot 18, which forms a further centering surface, forms a stop for a corresponding complementary centering surface 40 of the respective charging plug 11 or 12, which is formed by a front edge of the charging plug 11, 12.

[0047] When the charging plug 11 or 12 is accommodated in the guide slot 18, its front area 26 is preferably located completely within the guide slot 18.

[0048] The movable guide slot 18 is provided with a locking element 42 in the form of a pawl, which is designed to lock the guide slot 18 in its extended position. The locking element 42 comprises a protruding portion 44 at one end, which, when the guide slot 18 is extended, engages in a corresponding recess in the charging connection unit 10 and thereby assumes a locking position. The locking position of the locking element is in the Fig. 1 and Fig. 2 shown.

[0049] This fixes the guide slot 18 in its extended position in the charging connection unit 10 and creates a resistance or counterforce to the force exerted on the guide slot 18 during the plugging process. This allows the charging plug 11 or 12 to be pushed into the guide slot 18 and centered in the process without displacing the guide slot 18 backward or inward, i.e., into the charging connection unit 10.

[0050] At the other end of the locking element 42, a release surface 46 in the form of a protruding knee is formed, which is actuated by a corresponding release surface 48 at the front end of the charging plug 11 or 12 when the latter reaches its end position within the guide slot 18. The release surface 48 of the charging plug 11 or 12 is pressed against the release surface 46 of the locking element 42, so that the latter is released from its locked position.

[0051] In the embodiment shown here, the locking element 42 is designed in the manner of a rocker, which is pivotally mounted at its center about a pivot axis 52. As soon as the release surface 46 is pressed backward or inward, the protruding portion 44 located at the other end of the locking element 42 pivots about the pivot axis 52 from the locking position to an unlocking position. This means that the guide slot 18 is unlocked by the release surface 48 of the charging plug 11, 12 as soon as the charging plug reaches its end position upon insertion into the guide slot 18.

[0052] In the further course of the plugging-in process, the charging plug 11 or 12 is pushed into the charging connection unit 10 together with the unlocked guide slot 18, whereby the electrical contact elements 13, 13a of the charging connection unit 10 are pushed or plugged into one another with the complementary electrical contact elements 14, 14a or 15 of the charging plug 11 or 12 used.

[0053] The Fig. Figures 3-5 show the sequence of plugging the charging plug 11, 12 into the charging connection unit 10. The sequence is shown here using the AC charging plug 12 as an example. However, it also applies in the same or analogous manner to the DC charging plug 11.

[0054] First, the charging plug 12 is roughly positioned in the inlet opening 21 of the guide slot 18, as shown in Fig. 3. The locking element 42 is in the locked state and thereby fixes the extendable guide slot 18 in its extended position. The insertion funnel formed by the first centering surface 20 allows the charging plug 12 to be inserted into the guide slot 18 without any particular dexterity.

[0055] When pushed in further, the charging plug is secured by the screws described above and inserted into the Fig. 1 and Fig. 2 centering surfaces 20, 30, 36, 38 shown within the guide slot 18. This aligns the charging plug 12 with its electrical contact elements 15 with the mating face of the charging connection unit 10, which is formed by its electrical contact elements 13.

[0056] By centring, which is carried out when inserting the charging plug 12, first on the centring surfaces 20 and 30, then on the centring surface 36 and finally on the centring surface 38 (see Fig. 2), in particular, a compensation of an angular offset of the charging plug 12 with respect to the charging connection unit 10 is achieved, which is usually present in the previous rough positioning.

[0057] Fig. Figure 4 shows the charging plug 12 in its reached final position in the extended guide slot 18, in which it is centered. Upon reaching the centered position, the charging plug 12 unlocks the locking element 42 with its front release surface 48, as described above with reference to the Fig. 2 described.

[0058] As in the Fig. As shown in Figure 2, during unlocking, the release surface 46 at one end of the locking element 42 is pushed backward or inward by the release surface 48 of the charging plug 12. This moves the protruding portion 44 at the other end of the locking element 42 downward, thereby unlocking the locking element 42. The locking element is now in an unlocked position, so that the guide slot 18 is unlocked and can thus be moved within the charging socket.

[0059] In a next step, the charging plug 12 is pushed together with the now unlocked guide slot 18 in the charging connection unit 10 backwards or inwards into its charging position, which is shown in Fig. 5. In the charging position, the electrical connection between the charging plug 12 and the charging connection unit 10 is established, and the charging plug 12 is locked in its charging position. After the charging plug is locked with the retracted guide slot 18 in the charging position, the charging process is started or carried out.

[0060] The process described here also applies analogously to the DC charging plug 11.

[0061] The locking of the guide slot 18 remains intact when the charging process is completed and the charging plug 11 or 12 is removed from the charging connection unit 10. This means that the guide slot 18 remains immersed in the charging connection unit 10 and is locked into place. This allows the charging flap unit 16 to be closed after the charging plug 12 is removed without any further steps being necessary.

[0062] As an alternative to locking the guide slot 18 in its retracted position, it is not locked there. This allows the guide slot 18 to move into its extended position together with the charging plug 11, 12 when it is removed, where it is locked by means of the locking element 42 as described above.

[0063] This alternative is in Fig. 6. An actuating element 54 in the form of a projection is arranged on the loading flap 16b of the loading flap unit 16 such that, when the loading flap 16b is closed, it presses against the protruding portion 44 of the locking element 42 in the charging connection unit 10, thereby moving the locking element 42 into its unlocked position. This unlocks the extended guide slot 18, as shown in the figure.

[0064] After unlocking the locking element 42, the inner side 56 of the closing charging flap 16b presses against the guide slot 18, so that the latter is pushed into its retracted position within the charging connection unit 10. The closing charging flap unit 16 moves the guide slot 18 back into the charging connection unit 10.

[0065] The charging flap unit 16 and the protruding portion 44 of the locking element 42 are arranged such that the protruding portion 44 can also be manually operated, for example, with a finger, when the charging flap unit 16 is open. This allows, for example, in the event of a malfunction, the guide slot 18 to be moved back into the charging connection unit 10 and the charging flap 16b to be closed.

[0066] Fig.Figure 7 shows a further preferred embodiment of the invention. The guide slot 18 is formed by an arrangement of wedge-shaped segments 58 that can be moved into and out of the charging connector unit 10. The wedge-shaped segments 58 are designed as conical shaped jaws and are slidably mounted in the charging connector unit 10. Their inner sides form guide or centering surfaces 62 for the front region 26 of the charging plug 11 or 12.

[0067] The wedge-shaped segments 58 surround the charging plug 11, 12 when it is placed between them, being evenly spaced from each other. Due to their wedge shape, the segments 58, in their extended position, are relatively far apart from the outer contour of the front area 26 of the charging plug 11, 12. As a result, the charging plug can initially be positioned relatively imprecisely on the charging connection unit 10 in the area of ​​the segments 58.

[0068] Due to their wedge shape, the segments 58 with their centering surfaces 62 center the charging plug 11, 12 between them as it is inserted and are pushed into the charging connection unit 10 when the charging plug 11, 12 is inserted. The wedge-shaped segments 58 close as the charging plug 11, 12 is progressively inserted, as they are moved toward each other as they are pushed into the charging connection unit 10.

[0069] The charging plug 11, 12, which is held between the segments 58, is clamped and aligned. In this way, the wedge-shaped segments 58 center the charging plug 11, 12 with respect to the plug face or the electrical contact elements 13, 13a of the charging connection unit 10.

[0070] In the example shown here, three wedge-shaped segments 58 are provided, which form the guide slot 18. In principle, however, only two or more than three wedge-shaped segments 58 can be provided as the guide slot 18.

[0071] The charging connection unit 10 with its extendable guide slot 18 simplifies or automates the haptically and sensorically complex plugging process when charging an electrically powered vehicle. List of reference symbols: 10 Charging connection unit 11 DC charging plug 12 AC charging plugs 13, 13a electrical contact elements of the charging socket 14, 14a electrical contact elements of the DC charging plug 15 electrical contact elements of the AC charging plug 16 Loading flap unit 16a Hinge arm 16b Cover or loading flap 18 Guide scenery 20 first centering surface 21 Entrance opening 22 Top of the charging plug 24 Side surfaces of the charging plug 26 front area of ​​the charging plug 28 recess 30 second centering surfaces 32 Side surfaces of the DC charging plug 34 Bottom of the charging plug 36 third centering surface 38 fourth centering surface 40 complementary centering surface of the charging plug 42 Locking element 44 protruding section 46 Release surface of the locking element 48 Release surface of the charging plug 52 axis of rotation 54 Actuating element 56 Inside of the tailgate 58 wedge-shaped segments 62 centering surfaces of the segments S Plug direction

Claims

[1] Charging connection unit for an electric vehicle, comprising an arrangement of electrical contact elements (13, 13a) for establishing an electrical plug connection with complementary electrical contact elements (14, 14a, 15) of a charging plug (11, 12) to be connected to the charging connection unit (10), a charging flap unit (16) movable between a closed state and an open state to cover the electrical contact elements (13, 13a) of the charging connection unit (10) and to release them for a charging process, characterized by an extendable guide slot (18) for receiving the charging plug (11, 12) in the extended state and then moving back into the charging connection unit (10) together with the received charging plug (11, 12) to establish the electrical plug connection, wherein the guide slot (18) is designed such that it is automatically extended when the loading flap unit (16) is opened. [2] Charging connection unit according to claim 1, characterized by that the guide slot (18) comprises a funnel-shaped centering surface (20) which is designed to center the charging plug (11, 12) as it is progressively inserted into the guide slot (18). [3] Charging connection unit according to claim 2, characterized by that the guide slot (18) comprises at least one further centring surface (30, 36, 38) which is arranged behind the funnel-shaped centring surface (20) in the plug-in direction (S) of the charging plug (11, 12) to be inserted and is aligned parallel to the plug-in direction (S), wherein - the further centring surface (36) at least partially surrounds a front plug-in area of ​​the charging plug (11, 12) during progressive insertion and contacts it for guidance; and / or - the further centring surface (30) is formed on both sides of a recess (28) provided in the guide slot (18), which extends in the plugging direction (S) and contacts the charging plug (11, 12) on two side surfaces (24, 32) as it is inserted. [4] Charging connection unit according to one of the preceding claims, characterized by that the guide slot (18) can be locked in its retracted position in the charging connection unit (10) and is designed such that it remains in its retracted position when the charging plug (11, 12) is removed. [5] Charging connection unit according to one of the preceding claims, characterized by a locking element (42) which automatically fixes the guide slot (18) in its extended position and is unlocked by the charging plug (11, 12) when the latter reaches its end position when inserted into the guide slot (18). [6] Charging connection unit according to claim 5, characterized by that the locking element is designed such that it can be unlocked by the closing loading flap unit (16) when the guide slot (18) is extended, and / or can be unlocked manually when the guide slot (18) is extended. [7] Charging connection unit according to one of claims 1, 5 or 6, characterized by in that the guide slot (18) comprises a plurality of wedge-shaped segments (58) which are arranged in such a way that they surround the received charging plug (11, 12) and are shaped in such a way that they close when they move into the charging connection unit (10) in the direction of the charging plug (11, 12) in order to align it and clamp it between them. [8] Method for producing an electrical plug connection with a charging connection unit of an electric vehicle, comprising the steps: Opening a lockable charging connection unit (10); Extending a guide slot (18) from the charging connection unit (10) and locking the guide slot (18) in its extended position; Inserting an external charging plug (11, 12) into the extended guide slot (18); Unlocking and moving the extended guide slot (18) together with the charging plug (11, 12) into the charging connection unit (10) so that it reaches a retracted position in which the electrical plug connection is established, wherein the guide slot (18) is automatically extended when the charging connection unit (10) is opened. [9] Method according to claim 8, characterized by that the guide slot (18) remains in its retracted position when the charging plug (11, 12) is removed from the charging connection unit (10). [10] Method according to claim 8, characterized bythat the extended guide slot (18) is unlocked by a closing charging flap (16b) of the charging connection unit (10) after the charging plug (11, 12) has been removed in order to reach its retracted position.

Images