High-voltage connection arrangement and corresponding high-voltage system

Abstract

The invention relates to a high-voltage connection arrangement (400) arranged in a vehicle, comprising a high-voltage conductor (200) and a plurality of clamps (100). Furthermore, the invention relates to a high-voltage system (500), in particular a power distributor, arranged in a vehicle, comprising a plurality of electrical components (510), a structural part (520), in particular a housing (521), and at least one corresponding high-voltage connection arrangement (400).

Description

Technical FieldThe invention relates to a high-voltage connection arrangement arranged in a vehicle, having a high-voltage conductor and a multiplicity of clamping clamps for the mechanical connection of the high-voltage conductor. Furthermore, the invention relates to a high-voltage system arranged in a vehicle, having a corresponding high-voltage connection arrangement, a multiplicity of electrical components and a structural part, in particular a housing.Prior ArtIn electric vehicles, the efficient and safe energy distribution is of decisive importance. From the prior art, therefore, high-voltage systems are known as high-voltage power distributors or high-voltage power distributors, so-called power distribution units (PDUs for short). These PDUs therefore serve for distributing currents and voltages to high-voltage loads. Normally, contactors for controlling outputs of the PDU are used for the active distribution.To distribute the currents within the high-voltage system, in particular the PDU, busbars made of stamped and bent metal sheets-as known, for example, from DE 197 15 824 A1 or from DE 20 2015 103 854 U1-are usually used as high-voltage conductors. These busbars connect a plurality of electrical components, in particular HV components, arranged in a housing of the high-voltage system.In the case of a complex three-dimensional arrangement of these electrical components within the housing, however, the usual busbars abut their boundaries, since these are only deformable to a limited extent.Therefore, attempts have been made in the prior art to develop alternative busbars. For example, EP 3 347 243 B1 discloses a busbar made of a three-dimensionally bent wire which has a round cross section. In this case, a plurality of contact regions are formed into the busbar in order to enable the busbar to be connected to electrical components. These contact areas are mechanically formed into the wire by pressing, pressing and / or punching.However, the known solutions for connecting high-voltage conductors are very complicated. It would therefore be desirable to further develop the known solutions in such a way that they can be used more easily and flexibly.In other remote technical fields, the use of circular conductors as lightning arresters is fundamentally known. Lightning arresters of this type are fastened, for example, by clamping clamps. For example, a corresponding lightning arrester is known from DE 20 2013 004 927 U1.SUMMARY OF THE INVENTIONThe invention is therefore based on the object of specifying a connection of a high-voltage conductor which eliminates the aforementioned problems and disadvantages of the prior art. In this case, it is in particular the object of the present invention to provide a high-voltage connection arrangement having a corresponding connection and a high-voltage system which is based thereon.These objects are achieved by the subject matters of the independent claims. Further possible embodiments of the invention are specified in particular in the dependent claims.The solution according to the invention consists in particular in specifying a high-voltage connection arrangement which is arranged in a vehicle and has a high-voltage conductor with a round cross section and a multiplicity of clamping clamps for the electrical and / or mechanical connection of the high-voltage conductor. The clamping clamps have two at least substantially plate-shaped leg sections arranged one above the other for one-sided fastening of the clamping clamp. The plate-shaped leg sections are therefore configured to fasten the clamping clip to a component, for example an electrical component or a structural part. Furthermore, the clamping clamp has a receiving portion connecting the two leg portions for circumferentially receiving, in particular enclosing, the high-voltage conductor. The receiving section is therefore designed to receive, in particular enclose, the high-voltage conductor.A high-voltage conductor is in particular a high-voltage busbar for transmitting energy in the high-voltage range of more than 60 volts, preferably up to 1.5 kV. The term "high voltage" is also abbreviated below as "HV". The clamping clamp is thus suitable or designed for use in the high-voltage range of more than 60 volts.The high-voltage conductor with a round cross section can be, in particular, a round wire. The high-voltage conductor is formed in particular from metal or a metal alloy with a high electrical conductivity, such as copper.The vehicle is in particular an electric vehicle which can be driven with electrical energy. This can preferably be a motor vehicle. Alternatively, a rail vehicle, watercraft or aircraft would also be conceivable. However, it is particularly preferably a motor vehicle, and in particular a truck.The plate-shaped leg sections are in particular arranged one above the other in such a way that they lie two-dimensionally one above the other. By means of the plate-shaped leg sections, the clamping clamp is designed for one-sided fastening. This means that the clamping clamp is preferably fastened only on one side. In other words, the clamping clamp correspondingly preferably has only one fastening region which is formed by means of the two plate-shaped leg sections.When the high-voltage conductor is arranged in the receiving section, it extends through the receiving section. If the high-voltage conductor is formed with a round cross section, the receiving section is correspondingly formed at least substantially cylindrically. More generally, the shape of the receiving section is adapted to the outer shape of the high-voltage conductor or is formed complementary thereto. Particularly preferably, a press fit is formed between the receiving section and the high-voltage conductor.Preferably, the high-voltage conductor is formed at least substantially completely, i.e. continuously, in particular also at fastening regions, with a round cross section.The electrical connection serves to electrically connect the high-voltage conductor to another component, in particular an electrical component. The mechanical connection serves to mechanically connect the high-voltage conductor to another component, in particular a structural part.By means of the clamping clamp, a simple fastening and connection of the high-voltage conductor can be effected. For this purpose, the high-voltage conductor no longer has to be provided with contact regions by pressing, pressing and / or punching, that is to say by mechanical action, as in the prior art. Rather, a continuous round wire can be used as a high-voltage conductor. The choice of the fastening regions is also free in this way and does not have to be defined in advance. In particular, the plate-shaped leg sections and the receiving section enable an uncomplicated and secure fastening and connection of the high-voltage conductor. In addition, a rotational or translatory tolerance compensation in the installation is possible by means of the clamping clamp. Such a tolerance compensation is not possible in the case of round wires with stamped fastening regions.According to an advantageous development of the invention, the leg sections have a common fastening bore which extends through the two leg sections. Preferably, at least one of the two leg sections has a clamping disk region which is coaxial to the bore, in particular of annular design, and which is prestressed upward.By means of the common fastening bore, both leg sections can thus be fastened simultaneously to a component, in particular an electrical component or a structural part. For this purpose, only one fastening element, for example a fastening screw, is necessary.The fastening bore runs in particular perpendicular to the two plate-shaped leg sections.Due to the prestressed clamping disk region, the corresponding leg section has a clamping disk function. Similar to a disk spring, the prestressed clamping disk region counteracts loosening of the fastening, for example of the screw connection. In particular, the prestressed clamping disk region is designed to maintain a sufficient prestress in the connection by means of spring force. Thus, the prestress of the screw connection between leg section and component is maintained for a long time.A further surprising effect of the clamping disk region lies in an improved contact quality. The clamping disk region thus enables an improved contact quality when transmitting electric current.In an advantageous development of the invention, one of the leg sections is designed as a support leg and the other leg section is designed as a clamping leg. The support leg preferably merges tangentially into the receiving section and the clamping leg preferably merges via a curved region and an inflection point into the receiving section.The support leg is the leg which comes into direct contact with the component, in particular the electrical component or the structural part. Since the support leg merges tangentially into the receiving section, the support leg has a longer plate-shaped region than the clamping leg. As a result, the contact area between the support leg and the component is large.Preferably, the clamping leg has the clamping disk region. In particular, the clamping leg has the clamping disk region on a side opposite the support leg. The curved region creates a distance from the clamping leg to the high-voltage conductor and to the support leg. This simplifies the formation of an interference fit between the clamping clamp and the high-voltage conductor.Independently thereof, the curved region preferably has a similar, in particular at least substantially the same, radius of curvature as the receiving portion.The receiving section preferably has an at least substantially circular-arc-shaped cross-sectional contour. At the inflection point, a left-hand bent curvature changes to a right-hand bent curvature or vice versa. In particular, at the inflection point, the curved region merges into the receiving section.According to an advantageous development of the invention, the receiving section has a curvature of less than 350°, preferably less than 330°, particularly preferably less than 300°. Particularly preferably, the receiving section has at least substantially a 270° curvature. Regardless, the radius of curvature is generally preferably constant.With the described curvatures, on the one hand, the contact area with the high-voltage conductor is large. On the other hand, due to the open region without curvature, a good connection of the clamping clamp to the high-voltage conductor can take place, for example by means of a press fit.In an advantageous development of the invention, the clamping clamp has a geometry, in particular a recess, for connecting a measuring element for measuring a voltage and / or a current and / or a temperature of the clamping clamp.For example, the geometry can be a geometry for a plug contact. The measuring element can be, in particular, an NTC (negative temperature coefficient) resistor, i.e., a thermistor. This conducts the electric current better at high temperatures than at low temperatures.According to an advantageous development of the invention, the receiving section has circumferentially running, in particular continuous, slots.The slots thus run along the receiving section and extend completely through the material of the receiving section. The depth of the slots thus corresponds to the height of the receiving section. The receiving portion is consequently formed from a plurality of webs which are separated from one another by the slots.As a result, the receiving section can be bent better and can thus be adapted to the outer contour of the high-voltage conductor.Preferably, the slots extend over at least 180° of the curvature of the receiving section. Particularly preferably, the slots run over at least 225° of the curvature of the receiving section.According to an advantageous development of the invention, the clamping clamp is configured monolithically.The clamping clamp is thus completely formed jointly, wherein this is formed bent from a common sheet metal, for example.The clamping clamp is thus preferably formed monolithically in one piece.According to an advantageous development of the invention, the clamping clamp is formed from copper or brass if it is formed in particular for the electrical connection of the high-voltage conductor. Alternatively, the clamping clamp is made of stainless steel or spring steel, if it is designed in particular for the mechanical connection of the high-voltage conductor.In other words, there are preferably clamping clamps for in particular electrical connection of the high-voltage conductor and clamping clamps for in particular mechanical connection of the high-voltage conductor. Apart from the material, however, the clamping clamps are preferably of the same design.Due to the construction of copper or brass, the clamping clamps are particularly well electrically conductive. Due to the configuration from stainless steel or spring steel, these are particularly well suited for mechanical connection, i.e. fixing of the high-voltage conductor.In an advantageous development of the invention, the clamping clamp is formed from plastic and is formed in particular for the mechanical and electrically insulating connection of the high-voltage conductor. The clamping clamp preferably has a steel insert.The clamping clamp made of plastic makes it possible to mechanically connect the high-voltage conductor without electrical contacting, i.e., in an electrically insulating manner. The clamping clamp is thus designed as an insulator. Thus, the clamping clip no longer has to be electrically insulated separately in order to electrically insulate the structural part.The steel insert in the clamping clamp increases the strength and rigidity of the clamping clamp, so that an adequate mechanical connection is ensured despite the plastic material.The high-voltage conductor is preferably a conductor with a round cross section. The high-voltage conductor is therefore preferably designed as a round wire, in particular as a copper round wire.Preferably, at least one of the plurality of clamping clamps is a clamping clamp made of copper or brass. Furthermore, at least one further of the plurality of clamping clamps is a clamping clamp made of stainless steel or spring steel. In addition, at least one further of the plurality of clamping clamps is preferably a clamping clamp made of plastic. In other words, the high-voltage connection arrangement comprises clamping clamps made of copper or brass, clamping clamps made of stainless steel or spring steel, and clamping clamps made of plastic.Thus, by means of the clamping clamps, an electrical connection of the high-voltage conductor and a mechanical connection of the high-voltage conductor can be carried out in a targeted manner. Preferably, an electrically insulating connection of the high-voltage conductor can also be carried out in a targeted manner.Furthermore, the object is achieved by means of a high-voltage system arranged in a vehicle, in particular a power distributor or power distributor, that is to say a so-called PDU (Power Distribution Unit). The high-voltage system has a plurality of electrical components, a structural part, in particular a housing, and at least one of the high-voltage connection arrangements described above. In this case, the clamping clamps are designed and arranged for the electrical, mechanical and / or mechanical and electrically insulating connection of the high-voltage conductor to the electrical components and / or the structure.The electrical components are in particular an electrical high-voltage component, such as high-voltage contactors, fuses, pyrotechnic elements.The plurality of electrical components and the high-voltage connection arrangement are arranged in particular in the housing.Particularly preferably, clamping clamps made of copper or brass are provided in order to implement an electrical connection of the high-voltage conductor to the electrical components. Furthermore, clamping clamps made of stainless steel or spring steel are preferably provided in order to enable the mechanical connection of the high-voltage conductor to the structural part, in particular the housing.Brief Description of the DrawingsThe different and exemplary features described above can be combined with one another according to the invention, provided this is technically expedient and suitable. Further features, advantages and embodiments of the invention are evident from the following description of exemplary embodiments and on the basis of the figures.The figures used to explain the exemplary embodiments show: FIG. 1 shows a schematic illustration of a high-voltage system according to the present invention; FIG. 2 shows an illustration of a high-voltage connection arrangement which can be used in the high-voltage system in FIG. 1 ; and FIG. 3 shows an illustration of a clamping clamp which can be used in the high-voltage connection arrangement.WAYS OF CARRYING OUT THE INVENTIONFIG. 1 schematically shows a high-voltage system 500. The high-voltage system 500 can be, in particular, a power distributor or power distributor, also referred to as a PDU (Power Distribution Unit). The high-voltage system 500 is designed for use in an electric vehicle.The high-voltage system 500 has a housing 521 as a structural part 520. A plurality of electrical components 510 are disposed in the housing 521. The electrical components 510 are connected to one another by means of a high-voltage connection arrangement 400. In this case, the high-voltage connection arrangement 400 is also connected to the housing 521 itself.FIG. 2 shows a more detailed view of a high-voltage connection arrangement 400, as can be used in the high-voltage system 500 shown in FIG. 1. The high-voltage connection arrangement 400 has a high-voltage conductor 200 and a plurality of clamping clamps 100. The clamping clamps 100 serve, on the one hand, for the electrical connection of the high-voltage conductor 200 to the plurality of electrical components 510. On the other hand, the clamping clamps serve for the mechanical connection of the high-voltage conductor 200 to the structural part 520 or the housing 521.Such clamping clamps 100 that serve for electrical connection are preferably made of copper or brass. Clamping clamps 100, which serve for the mechanical connection of the high-voltage conductor 200, on the other hand, are preferably formed from stainless steel or spring steel. In FIG. 1, the clamping clamps 100, which serve for electrical connection, are provided with the reference numeral 100 a. The clamping clamps 100, which serve for the mechanical connection of the high-voltage conductor 200, are provided with the reference numeral 100 b. The clamping clamps 100, which serve for the mechanical connection of the high-voltage conductor 200, can also be clamping clamps 100, which are designed for the mechanical and electrically insulating connection of the high-voltage conductor 200.As can be seen in FIG. 2, the high-voltage conductor 200 is designed as a round wire. This has in particular a continuously round cross section.FIG. 3 shows a more detailed view of a clamping clamp 100 which is designed for the electrical and / or mechanical connection of the high-voltage conductor 200.The clamping clamp 100 shown is formed monolithically in one piece. However, the clamp 100 has a plurality of functional portions. In particular, the clamping clamp 100 has a receiving portion 130. The receiving section 130 serves for circumferential receiving, in particular enclosing, the high-voltage conductor 200. The receiving section 130 has a corresponding curvature in order to receive the round high-voltage conductor. The receiving section 130 forms here, by means of the curvature, more precisely an at least substantially cylindrical receiving geometry for the high-voltage conductor 200. However, the curvature does not run continuously, i.e. by 360°, but rather only by approximately 270°. Independently of this, the radius of curvature is at least substantially constant.The receiving portion 130 has a plurality of circumferentially extending slots 131. As a result, the receiving section 130 is divided into a plurality of webs 132 which are separated from one another by the slots 131. The slots 131 are continuous, i.e. extend through the entire material thickness of the receiving section 130.The slots 131 improve the bending properties of the receiving section 130, so that the latter can be bent particularly easily for adaptation to the high-voltage conductor 200.Furthermore, the clamping clamp 100 has two at least substantially plate-shaped leg sections 110, 120 arranged one above the other. The leg sections 110, 120 serve for the one-sided fastening of the clamping clamp 100. For this purpose, the leg sections 110, 120 have a common fastening bore 119. The fastening bore 119 extends perpendicularly to the leg sections 110, 120 which are embodied in the form of plates and extends through both leg sections 110, 120.An upper leg section 120 is designed as a clamping leg 120. The clamping leg 120 merges via a curved region 121 and an inflection point 122 downstream of the curved region 121 into the receiving section 130. As can be seen in FIG. 3, the curved region 121 is bent counterclockwise and the receiving section 130 is bent clockwise accordingly after the inflection point 122. A distance from the leg section 110 is produced by the curved region 121, so that clamping of the high-voltage conductor 200 is possible.The other leg section 110 is designed as a support leg 110 and merges tangentially into the receiving section 130. As a result, the flat region of the leg portion 110 is formed to be longer than the flat region of the leg portion 120. This in turn leads to a larger surface area, so that particularly good fastening or connection is possible.The clamping leg 120 has a clamping disc region 129. The clamping disc region 129 is formed coaxially with the fastening bore 119 and is prestressed upward. In particular, the clamping disk region 129 is of annular configuration, as can be seen in FIG. 3. The clamping disk region 129 functions here like a disk spring and generates a prestress on a fastening element, for example a fastening screw, arranged in the fastening bore 119.Furthermore, the clamping clamp 100 can have a geometry 128 for connecting a measurement element 300, not shown in detail. The geometry 128 can be, in particular, a recess or a pocket. The measuring element 300 serves for measuring a voltage and / or a current and / or a temperature at the clamping clamp 100.It should be noted that the features of the invention described with reference to individual embodiments or variants, such as the type and configuration of the individual components and their precise dimensioning and spatial arrangement, can also be present in other embodiments, unless it is stated otherwise or is prohibited by itself for technical reasons. Furthermore, of such features of individual embodiments described in combination, not necessarily all features need to be realized in a respective embodiment.Reference numerals denote reference numerals100 Clamping clamps 110 Leg section 119 Fastening bore 120 Leg section 121 Curved region 122 Inflection point 128 Geometry 129 Clamping disk region 130 Receiving section 131 Slots 132 Webs 200 High-voltage conductor 300 Measuring element 400 High-voltage connection arrangement 500 High-voltage system 520 Structural part 521 Housing 510 Electrical components

Claims

High-voltage connection arrangement (400) arranged in a vehicle, having a high-voltage conductor (200) with a round cross section and a plurality of clamping clamps (100) for the electrical and / or mechanical connection of the high-voltage conductor (200), wherein the plurality of clamping clamps (100) has the following: two at least substantially plate-shaped limb sections (110, 120) arranged one above the other for fastening the clamping clamp (100) on one side; and a receiving section (130) connecting the two limb sections (110, 120) for circumferentially receiving, in particular enclosing, the high-voltage conductor (200).High-voltage connection arrangement (400) according to Claim 1, characterized in that the limb sections (110, 120) have a common fastening bore (119) which extends through the two limb sections (110, 120), at least one of the two limb sections (110, 120) having a prestressed clamping disc region (129) which is formed coaxially with respect to the fastening bore (119), in particular in the form of a ring.High-voltage connection arrangement (400) according to Claim 1 or 2, characterized in that one of the limb sections (110) is designed as a bearing limb (110) and the other limb section (120) is designed as a clamping limb (120), wherein the bearing limb (110) merges tangentially into the receiving section (130) and the clamping limb (120) merges into the receiving section (130) via a curved region (121) and an inflection point (122).High-voltage connection arrangement (400) according to one of the preceding claims, characterized in that the receiving section (130) has at least substantially a 270° curvature with preferably constant radius of curvature.High-voltage connection arrangement (400) according to one of the preceding claims, characterized in that at least one of the clamping clamps (100) has a geometry (128), in particular a recess, for connecting a measuring element (300) for measuring a voltage and / or a current and / or a temperature to the clamping clamp (100).High-voltage connection arrangement (400) according to one of the preceding claims, characterized in that the receiving section (130) has circumferentially running continuous slots (131).High-voltage connection arrangement (400) according to one of the preceding claims, characterized in that at least one of the clamping clamps (100) is of monolithic design.High-voltage connection arrangement (400) according to one of the preceding claims, characterized in that at least one of the clamping clamps (100) is formed from copper or brass and is formed in particular for the electrical connection of the high-voltage conductor (200), or in that the clamping clamp (100) is formed from stainless steel or spring steel and is formed in particular for the mechanical connection of the high-voltage conductor (200).High-voltage connection arrangement (400) according to one of Claims 1 to 8, characterized in that at least one of the clamping clamps (100) is formed from plastic and is in particular formed for the mechanical and electrically insulating connection of the high-voltage conductor (200), the clamping clamp (100) preferably has a steel insert.High-voltage system (500), in particular a power distributor, arranged in a vehicle, having a multiplicity of electrical components (510), a structural part (520), in particular a housing (521), and at least one high-voltage connection arrangement (400) according to one of the preceding claims, wherein the clamping clamps (100) are designed and arranged for the electrical, mechanical and / or mechanical and electrically insulating connection of the high-voltage conductor (200) to the electrical components (510) and / or the structural part (520).

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