Power supply cable for a vehicle

Abstract

Power supply cable (10) for electrically connecting a vehicle (12), in particular an energy storage device (11) of a vehicle (12), to a power supply device (16) providing electrical energy, the power supply cable (10) comprising -- a connecting line (13), -- a primary connector (14) which can be electrically coupled or is coupled to the connecting line (13) and has a vehicle connection (14A) for detachable electrical connection to the vehicle (12), in particular the energy storage device (11), -- a secondary connector (15) which can be electrically coupled or is coupled to the connecting line (13) and has an infrastructure connection (1) which is provided for detachable electrical connection to the power supply device (16), -- wherein the secondary connector (15) has an electrically and mechanically connectable and separable main part (3) and adapter part (4), -- wherein the adapter part (4) has the infrastructure connection (1), -- wherein the main part (3) is electrically connectable or coupled to the connecting line (13) and comprises a control logic (18) of the secondary connector (15) and at least one switching unit (17a, 17b) for interrupting and establishing an electrical connection between electrical conductors of the infrastructure connection (1) and the connecting line (13).

Description

[0001] The present invention relates to a power supply cable for electrically connecting a vehicle, in particular an energy storage device of a vehicle, wherein the connection can be established in particular with a power supply device. State of the art

[0002] Various approaches are known from the state of the art for the electrical charging of electric vehicles or hybrid vehicles (e.g., cars, trucks, boats, aircraft, two-wheelers, etc.). In an initial charging situation, the vehicle can be charged via a dedicated charging infrastructure, which in particular involves permanently installed charging stations. For example, such charging stations are implemented as charging columns or wall boxes. In an alternative charging situation, a permanent power socket is provided, such as those used in normal households for energy supply. For example, this is a (230V) Schuko socket or a socket designed according to other regional standards or customs, whereby a three-phase connection can also be provided.In this case, a connecting cable of the charging cable usually has an integrated control unit, also called an In-Cable Control and Protection Device (IC-CPD), which is located between the two connectors within the connecting cable. This integrated control unit is used to communicate with the vehicle and to enable and adjust the charging current. Unlike a charging station or wallbox, a Schuko socket generally does not have a communication line or other electrical safety measures through which the vehicle can communicate with the power supply device or monitor the power supply process. Disclosure of the invention

[0003] The power supply cable according to the invention enables use with different types of continuous voltage sources. In particular, the power supply cable can be used with different types of household sockets, requiring only one adapter element to be exchanged. This makes the power supply cable simple and flexible to use. Furthermore, the power supply cable can be manufactured easily and cost-effectively. Furthermore, product-specific homologation costs can be optimized for specific countries.

[0004] The power supply cable is used to electrically connect a vehicle, or an energy storage device of a vehicle, to a power supply device providing electrical energy (thus the vehicle can be charged and the supply cable acts as a charging cable) and / or to a consumer requiring electrical energy or another vehicle (thus the vehicle serves as an energy source for the consumer or the other vehicle and the supply cable acts as a power supply cable for the consumer or the other vehicle, e.g., when its battery is exhausted, etc.). The power supply cable has a connecting line and a primary connector. The primary connector can be electrically coupled to the connecting line (e.g., in the manner of an exchangeable adapter) or coupled, e.g., in a way that cannot be removed without damage (the primary connector can, e.g.,(also referred to as a charging plug if the supply cable is used in its function as a charging cable). The primary connector also has a vehicle connection for the detachable electrical connection to the vehicle, in particular the energy storage device. Furthermore, the energy supply cable has a secondary connector. The secondary connector can be electrically coupled to the connecting line (e.g., in the manner of a replaceable adapter) or is coupled, e.g., in a way that cannot be removed without damage. In addition, the secondary connector has an infrastructure connection designed for the detachable electrical connection to the energy supply device.

[0005] The secondary connector comprises a main part and an adapter part. The main part and the adapter part can be electrically and mechanically connected and separated. The adapter part contains the infrastructure connection. This allows different adapter parts to be used with the main part, allowing the secondary connector to be used with different household sockets, for example.

[0006] The main part is electrically connectable or coupled to the connecting line. Furthermore, the main part comprises control logic for the secondary connector and at least one switching unit for interrupting and establishing an electrical connection between electrical conductors of the infrastructure connection and the connecting line. Thus, in particular, the adapter part is free of control devices, in particular free of control devices used to adjust and control energy transmission through the power supply cable. In other words, the entire functionality of the secondary connector is preferably implemented in the main part, with the adapter part serving merely to provide the infrastructure connection.

[0007] For example, the main part has a housing with a recess into which the adapter element can be inserted.

[0008] The subclaims show preferred developments of the invention.

[0009] The adapter part preferably has an interface. The main part preferably has a mating interface. The interface and mating interface are electrically connectable to establish an electrical connection between the electrical conductors of the infrastructure connection and the connecting line. The interface and the mating interface, in particular, establish a plug-in connection. Furthermore, it is provided that the mating interface has plug contacts electrically connected directly to the switching unit. This provides a low-resistance and reliable electrical connection.

[0010] The plug contacts are particularly preferably integrally connected to the terminals of the switching unit or formed integrally with the terminals of the switching unit. Alternatively, the plug contacts are preferably screwed to the terminals of the switching unit. In particular, the plug contacts are welded to the terminals. This results in a compact unit with low electrical contact resistance.

[0011] The plug contacts are preferably male plug contacts that can be inserted into the female mating plug contacts of the adapter's interface. This creates an electrical connection between the interface and the mating interface. The use of plug contacts ensures a robust connection and ensures a reliable electrical connection.

[0012] The main part has at least one temperature sensor for monitoring the temperature of the plug contacts. In particular, the at least one temperature sensor is part of the mating interface of the main part. This allows the temperature of the plug contacts to be monitored to ensure that the temperature of the plug contacts is limited in the event of an overload.

[0013] The switching unit comprises, in particular, a first switching unit and a second switching unit. The first switching unit serves to switch phase conductors and / or neutral conductors of the supply cable. The second switching unit serves to switch a protective / equipotential bonding conductor of the power supply cable. The first switching unit and the second switching unit are, in particular, separately switchable. It is preferably provided that the switching units are designed to interrupt and connect the respective electrical conductors.

[0014] In an advantageous embodiment, the switching unit and, in particular, an optional sensor system are connected to a control logic circuit board. The switching unit can be controlled by the control logic. In particular, the switching unit is directly connected to the circuit board. This ensures optimal connection and reliable controllability of the switching unit. This also makes it easy and cost-effective to manufacture the secondary connector. Furthermore, it is preferably provided that no significant phase currents are conducted via the circuit board. This allows the use of a cost-effective standard circuit board.

[0015] It is particularly advantageous to connect the switching unit to the circuit board using a press-fit connection. Alternatively, a connection using a printed circuit board connector is also possible. This allows for simple and low-effort assembly. Furthermore, this ensures a direct connection between the switching unit and the circuit board, thus ensuring reliable control of the switching unit.

[0016] The secondary connector preferably has a residual current device. The residual current device is in particular part of the main part and serves to monitor the electrical current flowing through the secondary connector. The residual current device is particularly advantageously connected to the control logic board and serves, for example, to disconnect one or more electrical conductors in the event of a fault. The secondary connector preferably has one or two optional current sensors. The current sensors are in particular part of the main part and serve to measure the electrical current flowing through the secondary connector. The current sensors, which can be implemented, for example, by magnetic-inductive transformation using a coil, are particularly advantageously connected to the control logic board and serve, for example, to disconnect one or more electrical conductors in the event of a fault (e.g., the flowing charging current is greater than the current required by the vehicle).

[0017] Advantageously, the main part has a guide element, in particular a mechanical one. The guide element is designed for at least partial positive connection with a counter-guide of the adapter part. This allows for a particularly reliable mechanical connection between the adapter part and the main part. The guide element and the counter-guide, in particular, predetermine an assembly direction along which the adapter part is fastened to the main part. In particular, the guide element and the counter-guide element establish a positive connection in a direction transverse to the insertion direction of the interface and the counter-interface.

[0018] The adapter part preferably has optical or electrical components. In particular, the components can be capacitors or resistors. The components are designed to be detected by the main part and to be identified by the main part. Different adapter parts, i.e. adapter parts with different infrastructure connections, in particular have different components and can thus be recognized and differentiated by the control logic based on the component properties. This prevents, for example, comparable adapter parts from being operated on the main part and thus potentially being overloaded. The components are particularly advantageously integrated into the counter-guide. The guide element of the main part has, for example, electrical contacts for contacting the electrical components of the adapter part in order to thereby recognize the existing adapter element.

[0019] The main part preferably comprises a measuring coil unit with current measuring coils for monitoring the electrical current flowing through the secondary connector. In particular, the current measuring coils serve to detect an electrical current in the phases and in the protective / equipotential bonding conductor of the secondary connector. Short description of the drawing

[0020] Embodiments of the invention are described in detail below with reference to the accompanying drawings. In the drawing: Fig. 1 a schematic illustration of a power supply cable according to an embodiment of the invention, Fig. 2 a schematic perspective view of a secondary connector of the power supply cable according to the embodiment of the invention, Fig. 3 a schematic perspective view of an adapter part of the secondary connector of the power supply cable according to the embodiment of the invention, Fig. 4 is a schematic perspective view of a main part of the secondary connector of the power supply cable according to the embodiment of the invention, Fig. 5 is another schematic perspective view of the main part of the secondary connector of the power supply cable according to the embodiment of the invention, Fig. 6 is a schematic perspective view of a switching unit of the main part of the secondary connector of the power supply cable according to the embodiment of the invention, and Fig. 7 is a schematic perspective view of the switching unit, a residual current device and current measuring coils of the main part of the secondary connector of the power supply cable according to the embodiment of the invention. Embodiments of the invention

[0021] All figures are merely schematic representations of the device according to the invention or its components according to exemplary embodiments of the invention. In particular, distances and size relationships are not shown to scale in the figures. Corresponding elements in the various figures are provided with the same reference numbers.

[0022] Fig. 1 schematically shows a vehicle 12, which is, for example, a hybrid or electric vehicle and which has an energy storage device 11. The energy storage device 11 is to be charged here, for example, via a power supply device 16. The power supply device 16 in the Fig. In the case shown in Figure 1, this can be, for example, a wallbox that enables charging with three-phase alternating current, or a continuous voltage source, such as a household socket such as a Schuko socket, which enables single-phase charging, for example. A power supply cable 10 according to one embodiment of the invention is provided to connect the power supply device 16 and the energy storage device 11 or vehicle 12.

[0023] The power supply cable 10 has a primary connector 14 and a secondary connector 15, wherein Fig. 1 shows various variants of the secondary connector 15. A connecting line 13 is provided between the primary connector 14 and the secondary connector 15. The primary connector 14 serves for the electrical connection to the vehicle 12 and specifically to the energy storage device 11. Depending on its design, the secondary connector 15 serves for the connection to the various types of energy supply device 16.

[0024] The primary connector 14 has a vehicle connection 14A, which is provided for the indirectly or directly detachable wireless or wired electrical connection to the vehicle 12 or the energy storage device 11.

[0025] In the illustrated embodiment, the primary connector 14 also has an additional connection 9, via which a wireless and / or wired electrical connection can be established directly or indirectly in a detachable manner with an additional coupling 5 of the connecting line 13. In an alternative embodiment, the additional connection 9 and the additional coupling 5 can be omitted, so that the connecting line 13 is attached directly to the primary connector 14 and cannot be separated from it without causing damage.

[0026] In the illustrated embodiment, the power supply cable 10 can be coupled to various types of secondary connectors 15. Each secondary connector 15 has an infrastructure connection 1 and a cable connection 2, wherein the infrastructure connection 1 is designed for electrical connection to the power supply device 16. The secondary connector 15 can also be coupled to another electric vehicle. In this application, the additional vehicle, with its energy storage device, provides the necessary energy to the vehicle 12 to be charged and therefore acts as the power supply device 16.

[0027] The cable connector 2 serves for connection to the connecting line 13. For this purpose, the connecting line 13 has, for example, a coupling 6, wherein the coupling 6 and the cable connector 2 are detachably electrically connected. Thus, the secondary connectors 15 can be replaced easily and with little effort by simply breaking the connection between the coupling 6 and the cable connector 2. In principle, power supply cables 10 are also conceivable in which the secondary connector 14 is permanently connected (i.e., cannot be removed without causing damage) to the connecting line 13.

[0028] In Fig. 1 above shows that the infrastructure connection 1 of the secondary connector 15 in one embodiment can be, for example, a Type 2 connection for connection to a charging station or wall box (here, for example, a current flow from the infrastructure connection 1 to the vehicle 12 or from the vehicle 12 to the infrastructure connection 1 is possible). Fig. Figure 1 below shows, by way of example, that the infrastructure connection 1 of the secondary connector 15, in an alternative embodiment, can be a Schuko plug for connection to a household socket (here, too, for example, a current flow is possible from the infrastructure connection 1 to the vehicle 12 or from the vehicle 12 to the infrastructure connection 1). A secondary connector 15 for connecting to another vehicle is also possible in principle, but is not shown here.

[0029] In this exemplary embodiment, the connecting line 13 only has electrical conductors between the coupling 6 and the additional coupling 5, which establish an electrical connection between the coupling 6 and the additional coupling 5. These electrical conductors are, for example, copper conductors or aluminum conductors, or they are made of another material with high electrical conductivity and have electrical insulation. All electrical conductors are, for example, combined in a strand and preferably have a common sheath, which serves on the one hand as electrical insulation and on the other hand as mechanical protection. These conductors or the strand can also contain electrical shielding in order to protect the signals in the connecting line 13 from electromagnetic influences. Preferably, in this exemplary embodiment, no active or passive electrical components are provided in the connecting line 13.All components or logic modules (e.g. microprocessors, ASICs, etc.) and in particular active or passive electrical components are either part of the primary connector 14 and / or part of the secondary connector 15. This advantageously allows the connecting line 13 to be manufactured cost-effectively. An IC-CPD can therefore be expressly dispensed with in this exemplary embodiment. As a result, the power supply cable 10, despite its adaptability shown here (various secondary connectors 15 can be optionally connected), can be manufactured cost-effectively, compactly, simply, space-savingly and with less weight. Omitting an IC-CPD not only reduces weight, costs and handling, but also complex quality inspections and load tests, since it is no longer necessary to secure the sensitive electronics of the IC-CPD, for example, against being run over by other vehicles, e.g. trucks.This also advantageously reduces the risk of people tripping. It is understood that in other embodiments, an IC-CPD may be provided, which is then arranged, for example, within the connecting line 13.

[0030] Fig. Figure 2 schematically shows a variant of the secondary connector 15, which can be connected to a continuous voltage source. In the illustrated embodiment, the infrastructure connection 1 of the secondary connector 15 is designed as a Schuko plug. In order to be able to use the power supply cable 10 for different types of continuous voltage sources, the secondary connector 15 is divided into a main part 3 and an adapter part 4. The adapter part 4 is also separately Fig. 3 is shown schematically and different perspective views of the main part 3 are shown in Fig. 4 and Fig. 5. Furthermore, the example shown shows a cable connector 2 for connecting to a coupling 6 of the connecting line 13. Alternatively, a direct connection of the connecting line 13 to the secondary connector 15, i.e., a connection that cannot be severed without damage, can of course also be provided.

[0031] The adapter part 4 comprises the infrastructure connection 1. The main part 3 comprises all the logic elements of the secondary connector 15. Thus, the adapter part 4, in particular, can be manufactured simply and cost-effectively and preferably serves only to connect the main part 3 to the power supply device 16. Dividing the secondary connector 15 into adapter part 4 and main part 3 thus provides the possibility of connecting the secondary connector 15 to various types of household sockets simply and cost-effectively, since only the adapter part 4 needs to be replaced. All other parts of the power supply cable 10 remain unchanged.

[0032] Main part 3 and adapter part 4 are designed to be electrically and mechanically connectable. To establish an electrical connection, adapter part 4 has an interface 7a. Main part 3 has a mating interface 7b, with interface 7a and mating interface 7b being electrically connectable. This electrical connection establishes an electrical connection between the electrical conductors of infrastructure connection 1 and cable connection 2 or connecting line 13.

[0033] The mating interface 7b has male plug contacts 19, which are designed as pins of the mating interface 7b. The plug contacts 19 can be inserted into female mating plug contacts 20 of the interface 7a of the adapter part 4 to establish an electrical connection.

[0034] The mechanical connection between the main part 3 and the adapter part 4 is achieved by the main part 3 having a guide element 8b. The adapter part 4 has a counter-guide 8a, wherein the guide element 8b cooperates with a counter-guide 8a of the adapter part 4 for at least a partial positive connection. In the illustrated embodiment, the guide element 8b can be inserted into the counter-guide 8a along an assembly direction 100, wherein the assembly direction 100 is also provided for plugging together the plug contacts 19 of the counter interface 7b with the counter-plug contacts 20 of the interface 7a. The positive connection between the guide element 8b and the counter-guide 8a preferably acts in all directions except parallel to the assembly direction 100.

[0035] Fig. 5 shows a further view of the main part 3, wherein a part of a housing 25 of the main part 3 is not shown. The main part 3 has a control logic 18 of the secondary connector 15 and two switching units 17a, 17b (cf. Fig. 6 and Fig. 7) for interrupting and establishing an electrical connection between electrical conductors of the infrastructure connection 1 and the connecting line 13. The switching units 17a, 17b are connected to a circuit board 18a of the control logic 18 via press-fit contacts 22. The circuit board 18a contains control modules and / or electrical circuits of the control logic 18. Furthermore, the main part 3 has a residual current circuit breaker 21.

[0036] Fig. Figure 6 schematically shows the switching units 17a, 17b, which are combined in a common block. A first switching unit 17a and a second switching unit 17b are provided. The plug contacts 19 of the counter interface 7b are electrically connected directly to the switching units 17a, 17b. In particular, the plug contacts 19 are integrally connected to the outputs of the switching units 17a, 17b, for example, welded or screwed. It may also be advantageous to form the plug contacts 19 in one piece with the connections of the switching units 17a, 17b. This allows short connection paths to be achieved and minimizes the number of joints between the plug contacts 19 and the switching units 17a, 17b. The first switching unit 17a is designed to switch phase conductors and / or neutral conductors, while the second switching unit 17b is provided to switch a protective / equipotential bonding conductor.The two switching units 17a, 17b can be controlled separately by the control logic 18. Inputs 23 of the first switching unit 17a and the second switching unit 17b are connected to the cable connector 2 and the connecting line 13, respectively, for example by welding or crimping.

[0037] Also schematically shown is a temperature sensor 26, which serves to detect the temperature of one of the plug contacts 19. Preferably, several temperature sensors 26 are provided to detect the temperature of all plug contacts 19. The temperature sensors 26 are coupled to the control logic 18, in particular to the circuit board 18a. This allows the operating temperature of the plug contacts 19 to be detected, which advantageously limits the current load to prevent overheating of the plug contacts 19.

[0038] In Fig.Figure 7 schematically shows the first switching unit 17a, the second switching unit 17b, and the residual current device 21. The residual current device 21 serves to monitor the electrical current flowing through the secondary connector 15. The residual current device 21 is connected to the circuit board 18a via contact pins 24. The current flow is switched off, for example, by controlling the switching units 17a, 17b. A measuring coil unit 25 is also provided. The measuring coil unit 25 has current measuring coils designed to detect an electrical current through the secondary connector 15. In particular, this enables detection and / or current transformation of the phase current and / or the current flow through the protective / equipotential bonding conductor.

[0039] Preferably, it is also provided that the adapter part 4 has optical or electrical components (not shown). These components are in particular integrated into the counter-guide 8a and serve to uniquely identify the adapter part 4 by the control logic 18. For this purpose, the main part 3, in particular the guide element 8b, preferably has an element for detecting the optical or electrical components. The components are, for example, capacitors, resistors, or an ASIC. To detect the resistor or capacitance, this is connected to electrical contacts formed on the counter-guide 8a. Mating contacts, which are connected to the control logic 18, are attached to the guide element 8b in order to connect the resistor or capacitance to the control logic 18 when the adapter part 4 and the main part 3 are connected to one another.The control logic 18 is thus capable of making specific settings that match the infrastructure connection 1 characterized by the components. For example, an expected input voltage or a maximum drawable electrical power can be set.

Claims

[1] Power supply cable (10) for electrically connecting a vehicle (12), in particular an energy storage device (11) of a vehicle (12), to a power supply device (16) providing electrical energy, the power supply cable (10) comprising -- a connecting line (13), -- a primary connector (14) which can be electrically coupled or is coupled to the connecting line (13) and has a vehicle connection (14A) for detachable electrical connection to the vehicle (12), in particular the energy storage device (11), -- a secondary connector (15) which can be electrically coupled or is coupled to the connecting line (13) and has an infrastructure connection (1) which is provided for detachable electrical connection to the power supply device (16), -- wherein the secondary connector (15) has an electrically and mechanically connectable and separable main part (3) and adapter part (4), -- wherein the adapter part (4) has the infrastructure connection (1), -- wherein the main part (3) is electrically connectable or coupled to the connecting line (13) and comprises a control logic (18) of the secondary connector (15) and at least one switching unit (17a, 17b) for interrupting and establishing an electrical connection between electrical conductors of the infrastructure connection (1) and the connecting line (13). [2] Power supply cable (10) according to claim 1, characterized by that the adapter part (4) has an interface (7a) which can be electrically connected to a mating interface (7b) of the main part (3) in order to establish an electrical connection between the electrical conductors of the infrastructure connection (1) and the connecting line (13), wherein the mating interface (7b) has plug contacts (19) which are electrically connected directly to the switching unit (17a, 17b) [3] Power supply cable (10) according to claim 2, characterized by that the plug contacts (19) are integrally connected to terminals of the switching unit (17a, 17b), in particular welded, or formed integrally with the terminals of the switching unit (17a, 17b) or screwed to the terminals of the switching unit (17a, 17b). [4] Power supply cable (10) according to claim 2 or 3, characterized by that the plug contacts (19) are male plug contacts (19) which can be inserted into female mating plug contacts (20) of the interface (7a) of the adapter part (4) to establish an electrical connection. [5] Power supply cable (10) according to one of claims 2 to 4, characterized by that the main part (3) has at least one temperature sensor (26) for monitoring a temperature of the plug contacts (19). [6] Power supply cable (10) according to one of the preceding claims, characterized bythat the switching unit (17a, 17b) has a first switching unit (17a) for switching phase conductors and / or neutral conductors of the supply cable (13) and a second switching unit (17b) for switching a protective / equipotential bonding conductor of the supply cable (13). [7] Power supply cable (10) according to one of the preceding claims, characterized by that the switching unit (17a, 17b) is connected to a circuit board (18a) of the control logic (18), wherein the switching unit (17a, 17b) can be controlled by the control logic (18). [8] Power supply cable (10) according to claim 7, characterized by that the switching unit (17a, 17b) is connected to the circuit board (18a) by means of press-fit connections (22) or a circuit board connector. [9] Power supply cable (10) according to one of the preceding claims, characterized bythat the main part (3) has a residual current circuit breaker (21) for monitoring the electrical current flowing through the secondary connector (15). [10] Power supply cable (10) according to one of the preceding claims, characterized by that the main part (3) has a guide element (8b) which is designed for at least partial positive connection with a counter-guide (8a) of the adapter part (4). [11] Power supply cable (10) according to one of the preceding claims, characterized by that the adapter part (4) has an optical or electrical component, in particular an integrated circuit, a capacitor or a resistor, which is designed for detection by the main part (3) and for identification of the adapter part (4) by the main part (3), wherein the components are in particular integrated into the counter-guide (8a) or are connected by an electrical contact point. [12] Power supply cable (10) according to one of the preceding claims, characterized by that the main part (3) has a measuring coil unit (25) with current measuring coils for monitoring an electrical current flowing through the secondary connector (15).

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