Charging connection device, vehicle and emergency release procedure

Abstract

The invention relates to a charging connection device (100) comprising a charging socket (200) and a charging plug (300) that can be inserted into the charging socket (200) in an insertion direction (PID), as well as a locking mechanism configured to lock the charging plug (300) relative to the charging socket (200) during a charging process and to release it after completion of a charging process, wherein the charging socket (200) has a charging socket housing (210) and the locking mechanism comprises an arrangement of balls (212) that are arranged in receiving openings (211) of the charging socket housing (210) and are radially displaceable transversely to the insertion direction (PID), and an actuating sleeve (230) is arranged axially displaceably on the charging socket housing (210), the actuating sleeve having a section of larger inner diameter (231) and a section of smaller inner diameter (232), which Charging plug (300) has a charging plug housing (310),the actuating sleeve (230) has a section of larger outer diameter (311) and a section of smaller outer diameter (312), and the actuating sleeve (230) is movable back and forth by an actuator (250) between a release position (RP), in which the section of larger inner diameter (231) allows a radial outward movement of the balls (212), and a locking position (LP), in which the section of smaller inner diameter (232) forces a radial inward movement of the balls (212). The invention further relates to an electrically powered vehicle (400) with a charging connection device (100) and a method for emergency unlocking a charging connection device (100) of an electrically powered vehicle (400).

Description

[0001] The invention relates to a charging connection device according to the preamble of claim 1, a vehicle according to the preamble of claim 2, and a method for emergency unlocking of a charging connection device of an electrically operated vehicle during a charging process according to the preamble of claim 8.

[0002] Electrically powered vehicles require regular charging breaks, and these charging breaks differ from refueling breaks of conventionally powered vehicles in the following ways: Charging breaks take longer than refueling breaks. Unlike gas stations, charging stations are regularly operated without permanently present staff. The spatial density of charging stations, especially those with fast chargers, is lower than that of gas stations, so owners of electric vehicles often cannot choose where they charge their vehicles and are therefore forced to charge in potentially unsafe locations.

[0003] Electric vehicles, especially those in the premium segment, can be a highly visible and attractive target for unwanted visitors who may have an illegitimate interest in the vehicle, its occupants, or their property. This can lead to unpleasant or dangerous situations, particularly during charging stops at charging stations.

[0004] In the current state of the art, electrical safety, the integrity of the vehicle, the charging cable and the charging station are ensured by requiring that the charging process must be completed before the charging cable can be removed and that the vehicle can only be moved, i.e. driven away, once the charging cable has been manually unplugged, i.e. removed.

[0005] If a vehicle is parked at a charging station during a charging break and a user remains inside for security, and the user notices suspicious individuals near the vehicle, there is only one option. Leaving the area with the vehicle requires unlocking it and exiting at least to unplug the cable, thereby exposing both the user and the vehicle. While some vehicles currently allow the charging process to be canceled from inside, the user must still exit the vehicle and manually unplug the connectors before driving off. By initiating the charging process, the user has effectively "demobilized" themselves, and this state can only be ended by unlocking the vehicle and exiting it.

[0006] From GB 2501726 A a method for emergency unlocking of an electrical charging connection of an electrically operated vehicle during a charging process and a charging connection comprising a charging plug with a locking mechanism are known.

[0007] DE 10 2020 108 950 A1 discloses a method and a control device for the emergency unlocking of an electrical charging connection of an electric vehicle.

[0008] DE 696 07 548 T2 discloses a connector locking arrangement with a tubular composite section formed on a connector housing for attachment to or in relation to a mating connector; at least one ball holder cutout formed by the tubular composite section and open to the outer and inner circumferential surfaces of the tubular composite section; at least one locking ball received in the ball holder cutout such that the locking ball is displaceable in a radial direction to the tubular composite section and is prevented from running radially past or beyond the circumferential surface of the tubular composite section opposite the mating connector.

[0009] DE 24 47 088 A1 discloses a coupling with a movable part in the form of a ball sleeve, which interacts with a fixed part in the form of a spindle with recesses for the balls, and with a tubular outer slide which slides on the movable part and holds the balls in the recesses in the fixed part in the locking position.

[0010] One object of the invention is to provide a charging connection device with an improved locking mechanism. A further object of the invention is to provide a method for the emergency unlocking of a charging connection device of an electrically powered vehicle during a charging process.

[0011] The object is solved according to the invention by a charging connection device with the features of the characterizing part of claim 1, a vehicle with the features of the characterizing part of claim 2, and a method for emergency unlocking of a charging connection device of an electrically operated vehicle during a charging process with the features of the characterizing part of claim 8.

[0012] Advantageous embodiments of the invention are the subject of the dependent claims.

[0013] Starting from a charging connection device comprising a charging socket and a charging plug that can be inserted into the charging socket in an insertion direction, as well as a locking mechanism designed to lock the charging plug relative to the charging socket during a charging process and to release it after completion of a charging process, it is proposed according to the invention that the charging socket has a charging socket housing and the locking mechanism comprises an arrangement of balls that are arranged in receiving openings of the charging socket housing and are radially displaceable transversely to the insertion direction, an actuating sleeve is arranged axially displaceable on the charging socket housing, parallel to the insertion direction, the actuating sleeve having a section of larger inner diameter and a section of smaller inner diameter, and the charging plug has a charging plug housing.which has a section of larger outer diameter and a section of smaller outer diameter, and the actuating sleeve can be moved back and forth by an actuator between a release position, in which the section of larger inner diameter allows a radial outward movement of the balls, and a locking position, in which the section of smaller inner diameter forces a radial inward movement of the balls.

[0014] In other words, it is proposed to implement the locking mechanism by means of a ball lock, in which an arrangement of balls in a release position, also referred to as "Release Position RP", allows both the insertion of the charging plug in a plug-in direction, also referred to as "Plug-In Direction PID", into the charging socket, as well as the removal of the charging plug from the charging socket, and in which the arrangement of balls in a locking position, also referred to as "Locking Position LP", prevents the removal of the charging plug from the charging socket, i.e., locks the charging plug in the charging socket.

[0015] The arrangement of balls is set in a series of receiving openings, advantageously distributed evenly around the circumference of the charging socket housing, and is radially displaceable inwards and outwards within these receiving openings. The receiving openings are designed such that the balls cannot fall inwards out of their respective receiving openings. The balls have a diameter larger than the wall thickness of the charging socket housing, so that the balls always protrude from their respective receiving openings on at least one side, i.e., inside the charging socket housing and / or outside the charging socket housing.

[0016] For example, a hollow cylindrical actuating sleeve is arranged on the outside of the charging socket housing in such a way that it encloses the charging socket housing and thereby prevents the balls from falling outwards from their respective receiving opening.

[0017] In order for the balls to move radially outwards in their respective receiving openings so that they do not protrude into the interior of the charging socket housing, but instead protrude outwards from the respective receiving opening, the actuating sleeve has, in addition to a section of smaller inner diameter that tightly encloses the charging socket housing, also a section of larger inner diameter that provides the space required for the balls.

[0018] The actuating sleeve is slidable back and forth on the charging socket housing parallel to the insertion direction of the charging plug. The actuating sleeve is in the release position when its larger inner diameter section is positioned over the arrangement of receiving openings and balls, because the balls can then move radially outwards away from the charging plug as it moves into or out of the charging socket. The larger inner diameter section of the charging socket housing can, for example, be in the form of a groove, which may further have, for example, angled groove flanks.

[0019] Similarly, the actuating sleeve is in the locking position when its smaller inner diameter section is positioned above the arrangement of receiving openings and balls. This is because the balls are then pressed radially inward by the actuating sleeve, protruding into the interior of the charging socket and engaging with a smaller outer diameter section of the charging plug housing adjacent to a larger outer diameter section. The balls engaging with the smaller outer diameter section of the charging plug housing prevent unauthorized removal of the charging plug from the charging socket. This is because the larger outer diameter section of the charging plug housing, which adjoins the smaller outer diameter section, cannot be moved past the balls, and the balls cannot move radially outward due to the smaller inner diameter section of the actuating sleeve positioned above it.The section with the smaller outer diameter of the charging plug housing can, for example, be designed in the form of a groove, which may further have, for example, angled groove flanks.

[0020] The actuating sleeve can be moved back and forth between the locked and unlocked positions on the charging socket housing by an actuator, which may be, for example, a geared motor, a lifting relay, or another type of electric, hydraulic, or pneumatic actuator. Alternatively or additionally, the actuating sleeve can be moved in at least one direction by a spring element. For example, a spring element can be arranged so that it moves the actuating sleeve into the locked position without any external force, or so that it moves the actuating sleeve into the unlocked position without any external force.

[0021] For example, the actuating sleeve can be in the release position without external force, allowing the balls to move radially outwards because the section of the actuating sleeve with a larger inner diameter is located in the area of ​​the balls. When the charging plug is then inserted into the charging socket, this can be detected, for example, by a sensor, a switching contact, or similar device, triggering the actuator, which then moves the actuating sleeve into the locking position. This causes the balls from the section of the actuating sleeve with a smaller inner diameter to move radially inwards, engaging with the area of ​​the smaller outer diameter of the charging plug housing. In this way, the balls lock the charging plug into the charging socket.

[0022] If an emergency release command is given, the actuator is actuated again. When the actuator moves the actuating sleeve from the locking position to the release position, in which the section of the actuating sleeve with the larger inner diameter is again positioned over the arrangement of receiving openings and balls, the charging plug is unlocked and can be removed from the charging socket, for example, either by the weight of the charging plug and the attached charging cable or by the tractive force of the vehicle when starting to move. It is understood that a drive authorization lock must first be released before a drive gear can be engaged. This must be included as part of the emergency release routine, as explained below.The proposed locking mechanism is particularly suitable for 22 kW AC charging, where the vehicle already incorporates the electrical charging connection, including the cable, and a new locking mechanism can be used. Unlike one-sided locking mechanisms, such as those using a pin, a locking tab, or similar, the proposed locking mechanism offers the advantage of preventing jamming. The proposed invention is not suitable for DC fast charging, as the cable is an integral part of the system and uses a different locking mechanism.

[0023] The object of the invention is further achieved by an electrically operated vehicle equipped with a charging connection device of the type described according to the invention.

[0024] The current state of the art is that the charging plug is inserted into the charging socket approximately in the direction of the vehicle's transverse axis and at an angle from above.

[0025] In one embodiment of a vehicle according to the invention, the charging socket on the vehicle may be arranged such that the insertion direction is spatially aligned essentially in the direction of a vertical axis of the vehicle, in particular parallel to the vertical axis of the vehicle. However, the term "parallel to the vertical axis" should not be interpreted too strictly. The invention encompasses all embodiments in which the charging plug, due to its own weight and, if applicable, the weight of the charging cable, is able to detach from the charging socket by gravity and slide downwards out of the charging socket. Ejection of the charging plug by gravity can be achieved, for example, by installing the charging coupling in such a way that the charging plug is inserted into the charging socket from bottom to top. The charging plug with the freely dangling charging cable weighs at least 600 g.Therefore, if the friction of the charging plug in the charging socket exerts a force of less than 6 N, the plug will simply fall out after unlocking due to its own mass and gravity.

[0026] In another embodiment, the charging socket on the vehicle can be arranged such that the insertion direction is spatially aligned essentially in the direction of a longitudinal axis of the vehicle, in particular parallel to the longitudinal axis of the vehicle. Again, the term "parallel to the longitudinal axis" should not be interpreted too strictly. The invention encompasses all embodiments in which the charging plug can slide out of the charging socket without damage when the vehicle drives away in a direction opposite to the charging station. For example, the charging plug can be released by driving forward, as the charging coupling is installed so that the charging plug is inserted from back to front. After release, the vehicle can easily apply the necessary pulling force. A strain relief can protect the charging cable and the charging station.

[0027] In further embodiments, the charging socket on the vehicle can alternatively or additionally be arranged so that the insertion direction is variable. In other words, the charging socket on the vehicle can be movably mounted, for example, with a joint, so that it automatically aligns itself in the direction of a tensile force transmitted from the charging cable via the charging plug to the charging socket. This design minimizes the risk of damage to the vehicle should the charging plug become more difficult to remove from the charging socket than intended.

[0028] In certain configurations, the charging socket may alternatively or additionally be located at the front or rear of the vehicle. If the charging socket is located at the rear, for example, it can be advantageously installed in such a way that the charging plug points backwards and that, when the vehicle moves forwards, the charging plug can simply be pulled out without damaging the charging socket, the charging cable, or the charging station.

[0029] The charging coupling can be mounted in the vehicle, for example, so that it can rotate horizontally, allowing it to activate both when driving forwards and backwards. The rotation could be set in a preferred direction by means of a spring. If the charging socket is located at the rear of the vehicle, for instance, the preferred direction could be rearward, with the charging plug also being inserted into the socket from the rear. If a sufficiently large force were exerted by the vehicle moving backwards, the charging socket would rotate forwards, thus creating a pulling force in the charging cable against the direction of travel and allowing the charging plug to be pulled out of the socket.

[0030] A further embodiment of the invention serves to protect the vehicle from damage, in which the charging socket on the vehicle is arranged behind a charging flap that can be opened about a pivot axis parallel to a longitudinal axis of the vehicle. The charging flap would thus, for example, pivot upwards and could therefore no longer be damaged by the charging plug or charging cable if the charging plug is unplugged from the charging socket while the vehicle is being driven away.

[0031] According to the invention, a method for the emergency unlocking of a charging connection device of an electrically powered vehicle of the described type is further proposed, in which an emergency unlock command removes a driving authorization lock and actuates the actuator to release the locking mechanism of the charging connection device in order to unlock the charging plug in the charging socket. If a charging process is still active at the time of the emergency unlock command, it is understood that the emergency unlock command must first terminate the charging process before the driving authorization lock is removed and the charging plug is unlocked in the charging socket.

[0032] This procedure allows customers to leave the charging station in an emergency without leaving the vehicle and without having to manually unplug the charging connector. It can thwart robberies and increases drivers' sense of security.

[0033] Advantageously, in one embodiment of the inventive method, the emergency release command may actuate the actuator that moves the actuating sleeve back and forth, or a further actuator, to cause or accelerate the ejection of the charging plug. This allows the ejection of the charging plug to be carried out quickly and safely, and damage to the vehicle can be avoided.

[0034] In one embodiment of the inventive method, the emergency unlock command can lock all vehicle doors that are not locked at that time and / or initiate an emergency call. This ensures the safety of the occupants and summons help without delay, allowing the occupants to concentrate on driving away. Advantageously, location data can be transmitted with the emergency call.

[0035] Voice control can be advantageously used to trigger the emergency release command. This can be done, for example, via a fixed command such as "Perform emergency release of the charging cable." Alternatively, free text recognition of the voice input can be used, possibly with a confirmation question: "Help, I'm being threatened!" "Should I perform the emergency release of the charging cable? Then you can simply drive away without leaving the car. I've also locked the vehicle. The charging cable will be left behind. Should I perform the emergency release of the charging cable now?" "Yes." Then it is released.

[0036] The inventive method provides an emergency release function for the charging plug at the charging socket, accessible from inside the vehicle during a charging process. This function can optionally be offered only when occupants are detected in the vehicle by means of sensors (e.g., radar, ultrasound, camera, seat mats, seat belt switches, etc.). This function can be operated, for example, via touch control on a display, by voice command, by a dedicated switch, by an app, or by gesture control.

[0037] After the emergency release function is activated, i.e., after an emergency release command is entered, the charging process is terminated if it is still active. The charging plug is then mechanically unlocked on the vehicle side.

[0038] Subsequently, in certain embodiments of the invention, the charging plug can be forcibly ejected by a suitable mechanical means, for example by means of a pre-tensioned spring that is triggered, or by means of an actuator such as a motor that drives a mechanical ejection device, or by means of a hydraulically or pneumatically actuated ejection device.

[0039] Alternatively, the charging socket in the vehicle can be designed and arranged in such a way that an emergency release of the charging plug results in the release of a mechanical locking mechanism of the charging plug in such a way that the charging plug is released from the charging socket by its own weight and the weight of the charging cable by means of the force of gravity and slides downwards out of the charging socket.

[0040] Alternatively, the charging socket in the vehicle can be designed and arranged in such a way that an emergency release of the charging plug results in the release of a mechanical locking mechanism of the charging plug in such a way that the charging plug slides out of the charging socket without damage when the vehicle is driven away in a direction of travel opposite to the charging station.

[0041] The vehicle's immobilizer can then be deactivated, optionally informing the driver about the deactivation of the immobilizer, and further optionally indicating via text output and / or voice output that the charging cable will be left behind when driving off after emergency unlocking.

[0042] Exemplary embodiments of the invention are explained in more detail below with reference to drawings.

[0043] This shows: Fig. 1 schematically a charging connection device in a release position, Fig. 2 schematically the charging connection device in a locked position, Fig. 3 schematically a charging connection device with horizontal insertion direction, and Fig. 4 schematically a charging connection device with vertical insertion direction.

[0044] Corresponding parts are marked with the same reference symbols in the figures.

[0045] The Fig. 1 and Fig. Figure 2 shows the same charging connection device 100. It comprises a charging socket 200 and a charging plug 300. A male connector 220 is arranged in the charging socket housing 210 of the charging socket 200, and a female connector 320 is arranged in the charging plug housing 310 of the charging plug 300. To charge a vehicle 400, the charging plug 300 must be inserted into the charging socket 200 such that the male connector 220 and the female connector 320 are electrically connected to each other.

[0046] An actuating sleeve 230 is slidably arranged on the charging socket housing 210. In one direction, the force of a spring element 240 must be overcome, which thereby provides a restoring force acting on the actuating sleeve 230. Furthermore, the actuating sleeve 230 is operatively connected to an actuator 250, which is designed to move the actuating sleeve 230 axially back and forth on the charging socket housing 210, i.e., parallel to the insertion direction of the PID. The actuating sleeve 230 has a section of larger inner diameter 231, which is designed as a groove-shaped recess in a section of smaller inner diameter 232.

[0047] In the charging socket housing 210, a plurality of receiving openings 211 are arranged, and in each receiving opening 211 there is a sphere 212 whose diameter is larger than the wall thickness of the charging socket housing 210, so that the sphere 212 protrudes either outwards or inwards beyond the wall thickness of the charging socket housing 210.

[0048] The charging plug housing 310 of the charging plug 300 is designed such that its largest outer diameter is slightly smaller than the smallest inner diameter of the charging socket housing 210 of the charging socket 200. This allows the charging plug 300 to be inserted into the charging socket 200 in the insertion direction PID indicated by an arrow. The charging plug housing 310 has a section of smaller outer diameter 312, which is designed as a groove-shaped recess in a section of larger outer diameter 311.

[0049] In Fig. In position 1, the actuating sleeve 230 is in a retracted position against the force of the spring element 240, which represents a release position RP for the charging plug 200. In this release position RP, the section of the actuating sleeve 230 with the larger inner diameter 231 is located above the arrangement of receiving openings 211 and balls 212. This allows the section of the charging plug housing 310 with the larger outer diameter 311 to push the balls 212 radially outwards, thereby enabling the charging plug 300 to be inserted into or removed from the charging socket 200 in the insertion direction PID as required.

[0050] Fig. Figure 2 shows how the charging plug 300 is locked in the charging socket 200. When the charging plug 300 is fully inserted into the charging socket 200, the section with the smaller outer diameter 312 of the charging plug housing 310 is located below the arrangement of receiving openings 211 and balls 212. When the actuating sleeve 230 is moved into the locking position LP, the section with the smaller inner diameter 232 of the actuating sleeve 230 slides over the arrangement of receiving openings 211 and balls 212, thereby pressing the balls 212 radially inward. The balls 212 now protrude inward from the receiving openings 211, that is, into the charging socket housing 210, and are pressed into the section with the smaller outer diameter 312 of the charging plug housing 310.This locks the charging plug 300 in the charging socket 200 and prevents it from being removed until the actuating sleeve 230 is moved from the locking position LP to the release position RP, as shown in . Fig. Figure 1 shows that the movement of the actuating sleeve 230 is advantageously triggered by the action of the actuator 250.

[0051] The Fig. 3 and Fig. Figure 4 shows exemplary vehicles 400 in which the insertion direction of the PID is aligned according to the invention. In both embodiments, a charging flap 410 is located laterally on a vehicle 400 behind a vehicle door 420. The charging flap 410 can be pivoted about a vertical pivot axis 411 to open it. This provides access to the charging socket 200.

[0052] In Fig. 3 The charging plug 300 of a charging cable 330 is inserted into the charging socket 200 of the vehicle 400 in an approximately vertical insertion direction PID, that is, approximately parallel to the vertical axis Z of the vehicle 400, so that the charging plug 300 can fall out by gravity after the charging socket 200 has been unlocked.

[0053] In Fig. 4 The charging plug 300 of a charging cable 330 is inserted into the charging socket 200 of the vehicle 400 in an approximately horizontal insertion direction PID, that is, approximately parallel to the longitudinal axis Y of the vehicle 400, so that the charging plug 300 can be pulled out after the charging socket 200 has been unlocked by the movement of the vehicle 400 when driving away. Reference symbol list 100 charging connection device 200 charging socket 210 charging socket housings 211 Intake opening 212 balls 220 connectors 230 Actuating cuff 231 Section larger inner diameter 232 Section of smaller inner diameter 240 spring element 250 actuator 300 charging plugs 310 charging plug housing 311 Section larger outer diameter 312 Section of smaller outer diameter 320 connectors 330 charging cables 400 vehicles 410 Charging port 411 Swivel axis 420 vehicle door PID insertion direction RP Release Position LP locking position Y longitudinal axis Z vertical axis

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