High-performance connector socket and high-voltage distribution unit with a corresponding high-performance connector socket

Abstract

The invention relates to a high-performance connector (10) for megawatt coupling, particularly for an electric vehicle, comprising: a connector element (100) with a plurality of contact pin receptacles (110a, 120a, 130a, 140a, 150a) and associated contact pins (110, 120, 130, 140, 150); a circumferential collar (200) formed around the connector element (100) and laterally surrounding it, wherein the plurality of contact pin receptacles (110a, 120a, 130a, 140a, 150a) includes two DC contact pin receptacles (110a). Each of the two DC contact pin receptacles (110a) has a two-part megawatt DC contact pin (110). Furthermore, the megawatt direct current contact pin (110) has an outer part (111) and an inner part (112) which is detachably connected axially to the outer part (111).Furthermore, the invention relates to a high-voltage distribution unit (1) with a corresponding high-performance connection socket (100).

Description

Technical field The invention relates to a high-performance connector for megawatt coupling, in particular for an electric vehicle. Furthermore, the invention relates to a high-voltage distribution unit for energy distribution and / or energy conversion and / or energy protection in a vehicle with a corresponding high-performance connection socket. State of the art Charging ports for electric vehicles are known in the prior art. The transformation from combustion engine vehicles to electric vehicles, aimed at reducing dependence on fossil fuels and promoting sustainability in the transport sector, has also made the provision of efficient and versatile charging options crucial. This is particularly true for vehicles used in industrial and commercial applications, where time and power are critical. Against this background, efforts have been made to provide high-performance connectors that allow charging capacities in the megawatt range. A standard connector specification, or connector specification, has also been developed within the framework of the Megawatt Charging System (MCS). With its higher charging capacity, the new Megawatt Charging System (MCS) opens up the possibility of electromobility for a wide variety of vehicles. This includes the conversion of heavy commercial vehicles, special-purpose vehicles, marine vessels, and aircraft into electric vehicles. However, the connection sockets known from the state of the art are currently not suitable for such a diverse application. Description of the invention The invention is therefore based on the objective of providing a high-performance connection socket for megawatt coupling that has advantages over the aforementioned prior art. Furthermore, it is an object of the present invention to provide a corresponding high-voltage distribution unit which also has advantages over the prior art. These problems are solved by the subject matter 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 of providing a high-performance connector for megawatt coupling, especially for an electric vehicle. The high-performance connector has a connection element with a plurality of contact pin receptacles and associated contact pins. Furthermore, the high-performance connector has a circumferential collar that is formed around the connection element and surrounds the connection element laterally. The plurality of contact pin receptacles includes at least two DC contact pin receptacles. According to the invention, each of the two DC contact pin receptacles has a megawatt DC contact pin which is designed in two parts. The megawatt DC contact pin has an outer part and an inner part which is detachably connected axially to the outer part. The high-performance connector is designed to receive charging power in the megawatt range. Specifically, it is suitable for a (coupling) power of at least 1 megawatt, particularly between 2 and 4.5 megawatts. Furthermore, it is preferably suitable for a rated current of up to 3000 A and a rated voltage of up to 1500 volts DC. The high-performance connector is therefore a socket for electrical coupling in the megawatt range of an electric vehicle. It enables the connection of multiple electrical contacts and ensures a secure and efficient connection. The central connecting element of the high-performance connector is the connection element. This connection element is preferably a one-piece, and in particular a one-piece, molded element in which all contact pin receptacles of the high-performance connector are centrally arranged. The contact pin receptacles are designed to accommodate corresponding contact pins to establish an electrical contact. The contact pin receptacles include, in addition to the two DC contact pin receptacles, a protective conductor receptacle, a communication line receptacle, a PP (proximity pilot) contact pin receptacle and a CP (control pilot) contact pin receptacle. Accordingly, in addition to the megawatt DC contact pins, the contact pins have a protective conductor contact pin, a communication line contact pin, a PP contact pin and a CP contact pin. Regardless, the contact pin receptacles and the contact pins extend axially through the connector element. The connector element thus serves as a carrier for the contact pins and establishes the mechanical and electrical connection to a corresponding plug. The contact pin receptacles are features within the connection element that serve to receive and secure the respective contact pins. Each receptacle is assigned to a specific contact pin. The contact pins are electrical conductors arranged in the contact pin receptacles and are used to transmit electrical energy or signals. The megawatt DC contact pins are specifically designed for the transmission of megawatt DC current. Accordingly, they are designed for the transmission of at least 2 megawatts, preferably at least 3 megawatts, and particularly preferably at least 4.5 megawatts. The collar is preferably an essentially ring-shaped rim formed around the connecting element. The collar is designed to protect the connecting element from lateral impacts. Furthermore, the collar generally protects the connecting element, or the contact pins arranged in the connecting element, from external influences such as dust, moisture, or mechanical stress. The collar's essentially ring-shaped edge is formed by a circumferential wall. This circumferential wall is preferably designed to be complementary to a sleeve of the connecting element. For example, the sleeve of the connecting element has three rounded corners. Accordingly, the circumferential wall also has three rounded corners. Preferably, the collar projects axially beyond the connecting element when assembled. Preferably, the circumferential collar can be arranged on the connecting element in a replaceable manner. This allows the collar to be removed from the connecting element without damage. Furthermore, there is flexibility in selecting different materials for the collar depending on the application. For example, in areas subject to particularly high stress, the collar can be made of a particularly robust, especially hard, material. Depending on the application, it may also be necessary to make the collar from an electrically conductive material. Alternatively, the circumferential collar can also be formed integrally with the connecting element or a wall of a housing of a high-voltage distribution unit in which the high-performance connection socket is formed. According to the invention, the megawatt direct current contact pins are each designed in two parts, with an outer part and an inner part. The outer part is the portion extending outwards from the high-performance connector. Similarly, the inner part is the portion extending inwards from the high-performance connector. The interior of the housing of the high-voltage distribution unit on which the high-performance connector is located is considered an example of an interior. The inner part is preferably permanently connected to the connecting element 100. If the outer part is detached from the inner part, it can be removed from the connecting element and replaced. A detachable screw, crimp, or press connection can generally be used to connect the two parts. The outer part of the megawatt DC contact pin is susceptible to wear due to mechanical and environmental influences. However, to reliably conduct DC current in the megawatt range, it must always have a sufficiently undamaged surface. The detachable connection of the outer part allows for easy replacement if it becomes excessively worn or contaminated. Therefore, if the contact pins are damaged or worn, it is no longer necessary to replace the entire DC contact pin or the entire connection element, but only the heavily stressed outer part. According to an advantageous embodiment of the invention, the outer part has a connecting device, particularly in a lower axial region. Furthermore, the inner part has a complementary connecting device, particularly in an upper axial region. Preferably, the connecting device and the complementary connecting device are designed as rotatable connections, and in particular as bayonet fittings. The connecting device of the outer part and the complementary connecting device of the inner part are designed to form a rotatable connection. If the connecting devices are designed as a bayonet fitting, particularly quick and secure assembly and disassembly are possible with a simple rotational movement. Preferably, the outer part of the megawatt DC contact pin is inserted into the inner part of the megawatt DC contact pin. The two parts are then mechanically locked by a rotation. In an advantageous embodiment of the invention, a sealing seat, preferably the only one or the only ones, is formed on the inner part. The sealing seat is an area designed for the placement of a seal to seal the high-performance connector socket. The sealing seat(s) are only located on the inner part, i.e., the part of the megawatt direct current contact pins that is not replaced. Accordingly, when replacing the outer parts of the megawatt DC contact pins, it is not necessary to interfere with the sealing system of the high-performance connector. For example, the seal seat may have a shoulder and / or a groove. In particular, the seal seat may be designed to accommodate a radial seal. According to an advantageous embodiment of the invention, the inner part and the outer part are made of different materials. The inner and outer parts of the megawatt DC contact pin are therefore made of different materials, each specifically tailored to its respective function. The choice of material allows for optimization of electrical, mechanical, and thermal properties. For example, the inner part might be made of aluminum or an aluminum alloy, while the outer part might be made of copper, particularly CU-ETP, or a copper alloy. Alternatively, the inner and outer parts can be made of the same material, in particular copper, especially CU-ETP, or a copper alloy. It is particularly preferred that the outer part be made of copper, especially CU-ETP, or a copper alloy, regardless of the material of the inner part. Preferably, the outer part and / or the inner part is coated. One of the above-mentioned materials, in particular copper or aluminum, can be used as the base material to be coated. It is particularly preferred that the outer part is coated with a material that has better conductivity and / or higher strength than the base material. Preferably, the outer part is coated with Ag, a multilayer Ag / Sn / Ni layer, a two-layer Ag / Ni layer, a two-layer Pd / Ni layer, or Au. Particularly preferably, the outer part is coated with Ag, Ag / Ni, or Pd / Ni. Preferably, only the outer part is coated, or the outer and inner parts are coated differently. Preferably, the inner part is coated with Ag, a multilayer Ag / Sn / Ni layer, a two-layer Ag / Ni layer, a two-layer Pd / Ni layer, Au, Ni, or uncoated. Particularly preferably, the inner part is coated with Ag / Ni, Ni, or uncoated. The coating is preferably carried out in an electroplating bath. Since the outer and inner parts can be separated, it is possible to coat only the outer part and / or the inner part separately in the electroplating bath. According to an advantageous embodiment of the invention, the inner part is formed at least substantially from a solid material. The inner part is preferably formed from solid material, at least up to the complementary connection element. This means that the inner part consists essentially of a solid, continuous block of material, without significant cavities or material savings, particularly in the core area. The solid material minimizes electrical contact resistance, resulting in more efficient current transmission. This is especially advantageous at high currents, such as those encountered in megawatt applications. Furthermore, the solid material allows for uniform heat dissipation. This reduces the risk of overheating and improves the thermal stability of the high-performance connector. Overall, the use of solid material for the inner part enhances its electrical, thermal, and mechanical performance. In an advantageous further development of the invention, the outer part is designed entirely as a hollow body. In particular, the outer part is designed as a hollow body and the inner part as a solid. The outer part has an inner, preferably continuous, cavity and is especially preferably designed, at least substantially, as a hollow cylinder. The advantage here is that both the outer part, i.e., the shell of the outer part, and the inner part, i.e., the part of the body forming the cavity, can be used as electrical and / or mechanical contact surfaces. This enables transmission in the megawatt range. In an advantageous further development of the invention, the inner part is designed to be rotationally asymmetric. Preferably, the inner part has a plate-shaped area. This plate-shaped area preferably extends below the complementary connecting element. The plate-shaped area is particularly preferably the solid section of the inner part. The plate-shaped area is characterized by its flat and wide shape. The plate-shaped area allows for a large contact surface, thus creating a better contact area for electrical connections, which increases conductivity and reduces contact resistance. Due to the rotationally asymmetric design of the inner part, it is also rotationally resistant and can counteract the rotational force when the outer part is twisted relative to the inner part. A shoulder, particularly a shaft shoulder, is preferably arranged between the plate-shaped area and the complementary connection element. Independently of this, at least one sealing seat, particularly a radial sealing seat, is preferably provided in the area between the complementary connection element and the plate-shaped area. According to an advantageous embodiment of the invention, the outer part is rotationally symmetrical. Preferably, the outer part is at least substantially pin-shaped. The symmetry of the outer part ensures a uniform geometry along the axis of rotation, thus enabling easy insertion of a plug. In other words, the outer part has a pin-like structure characterized by an elongated cylindrical shape. According to an advantageous embodiment of the invention, a tool receptacle for receiving a tool for rotating the outer part relative to the inner part is formed in an upper region of the outer part. The rotation serves to loosen or fasten the outer part to the inner part. In other words, a tool holder is integrated into the upper part of the outer section. This holder serves primarily to positively engage a corresponding tool, which is specifically used for loosening or tightening the outer section to the inner section. This loosening or tightening is achieved by rotating the outer section relative to the inner section. The tool holder has a rotationally asymmetrical cross-section or shape. For example, the tool holder can be designed as a polygonal profile, a slotted or cross-shaped profile, or with special groove or cam structures. Regardless, the tool holder is preferably recessed into the upper region of the outer part. In other words, the tool holder is formed within the outer part. The tool for turning the outer part is then inserted into the outer part. By arranging the tool holder within the outer part, the contact surface of the outer part is protected. This increases the service life of the outer part. The upper region is generally defined as the area of ​​the outer part that points away from the inner part. Overall, the tool holder in the upper area of ​​the outer part enables safe and efficient assembly and disassembly of the outer part through precise guidance of a tool and ensures that the components are protected from damage. Preferably, the tool holder is not formed in one piece, and especially not as a single-piece, molded part, with the outer part. Rather, the tool holder can be formed as a separate part and arranged in the outer part. The solution according to the invention further comprises a high-voltage distribution unit for energy distribution and / or energy conversion and / or energy protection in a vehicle. The high-voltage distribution unit includes the following: several high-voltage components that are operated by means of high voltage, wherein the high-voltage components preferably comprise at least several high-voltage busbars and high-voltage switching devices for connecting or disconnecting individual high-voltage busbars. Furthermore, the high-voltage distribution unit has a housing that encloses the high-voltage components, the housing having a wall. The high-voltage distribution unit also includes one of the previously described high-performance connection sockets. Since the high-voltage distribution unit features one of the previously described high-performance connection sockets, all aspects and advantages of these sockets can be applied to the high-voltage distribution unit. In particular, the high-voltage distribution unit is therefore a high-voltage device for energy distribution. The high-voltage distribution unit is designed to connect a separate high-voltage (HV) battery to various electrical loads. The high-voltage distribution unit is therefore a technical system within the vehicle. It serves to distribute, convert, and / or protect high-voltage energy. Optionally, the high-voltage distribution unit can also perform energy conversion functions, such as converting direct current (DC) to alternating current (AC) or vice versa. In terms of energy protection, the high-voltage distribution unit protects the vehicle from overloads, short circuits, or other malfunctions through its integrated switching devices. The high-voltage distribution unit (PDU) is a device for distributing, converting, and / or protecting power within a vehicle. Also known as a PDU, it comprises several high-voltage components that operate using high voltage (HV). In particular, the high-voltage distribution unit preferably has at least two busbars, one for a positive and one for a negative high-voltage potential. The distribution unit is especially preferably equipped with multiple busbars. Furthermore, the high-voltage distribution unit preferably includes signal lines for communication and, optionally, cooling devices for cooling the busbars or the high-voltage components installed in the high-voltage distribution unit. The high-voltage distribution unit is preferably connected to, or connectable to, a voltage source, in particular a high-voltage (HV) vehicle battery, and to, or connectable to, multiple loads. The high-voltage distribution unit is therefore specifically not the HV vehicle battery itself. The high-voltage distribution unit then serves to transfer energy from the voltage source to multiple loads. The individual loads can be switched on and off separately using the high-voltage distribution unit. The switching elements, as high-voltage components, are arranged within the housing of the high-voltage distribution unit and can be implemented, for example, electromechanically, in particular as contactors, but also, in principle, purely electronically with power semiconductors. In summary, the high-voltage distribution unit is designed, at least, for energy distribution. Accordingly, the high-voltage distribution unit has several busbars and switching devices for connecting or disconnecting individual branches or loads. Furthermore, the high-voltage distribution unit can optionally include a DC-DC converter. This DC-DC converter is designed, for example, to convert the high-voltage direct current into the vehicle's electrical system voltage. Additional converters can also be integrated into the high-voltage distribution unit. The high-voltage connection socket according to the invention enables a safe and powerful coupling of the high-voltage distribution unit with external high-voltage systems. Brief description of the drawings The above-described, different, and exemplary features can be combined with one another according to the invention, insofar as this is technically sensible and suitable. Further features, advantages, and embodiments of the invention will become apparent from the following description of exemplary embodiments and with reference to the figures. The figures used to illustrate the embodiments show: Fig. 1 a perspective view of a high-power connector; Fig. 2 a perspective view of a two-part megawatt DC contact pin, as can be used in the high-power connector shown in Fig. 1; Fig. 3 a top view of the DC contact pin shown in Fig. 2 in a disassembled state; and Fig. 4 a sectional view of the megawatt DC contact pin shown in Fig. 2 and Fig. 3 in the assembled state. Ways to implement the invention Fig. 1 shows a perspective view of a high-voltage distribution unit 1 with a high-performance connector 10. The high-performance connector 10 has a terminal element 100 and a collar 200. The collar 200 surrounds the connection element 100. Here, the collar 200 is shown as part of a wall 2a of a housing 2 of the high-voltage distribution unit 1. High-voltage components 3 are indicated inside the housing 2 of the high-voltage distribution unit 1. The collar 200 is shown here only as an example of a joint design with the wall 2a. It would also be conceivable that the collar 200 could be attached to the wall 2a. In any case, however, the connecting element 100 and the collar 200 are preferably two separate components. As can be seen in Fig. 1, the collar 200 surrounds the connecting element 100. In particular, the collar 200 is at least substantially ring-shaped, with the connecting element 100 arranged inside the ring. Thus, the collar 200 surrounds the connecting element 100 laterally. The collar 200 is open at an axial front face to receive a high-performance connector, for example, a high-performance charging connector. The high-performance connector can thus be axially plugged onto the high-performance connector socket 10. The connection element 100 has a plurality of contact pin receptacles 110a, 120a, 130a, 140a, and 150a for receiving corresponding contact pins 110, 120, 130, 140, and 150. Specifically, the connection element 100 has two megawatt DC contact pins 110 in the contact pin receptacles 110a. Furthermore, the connection element 100 has a protective conductor contact pin receptacle 120a with a corresponding protective conductor contact pin 120. The connection element 100 also has a communication line contact pin receptacle 130a with a corresponding communication line contact pin 130. Finally, the connection element 100 has a PP contact pin receptacle 140a with a corresponding PP contact pin 140. Furthermore, the connecting element 100 has a CP contact pin receptacle 150a with a corresponding CP contact pin 150. The high-performance connector socket 10 is designed in the plug specification shown with a charging power of up to 4.5 megawatts. As can also be seen in Fig. 1, the collar 200 projects axially beyond the connecting element 100 in the assembled state. Figures 2, 3 to 4 show representations of the megawatt DC contact pin 110. The megawatt DC contact pin 110 is designed in two parts and has an outer part 111 and an inner part 112. The outer part 111 and the inner part 112 are detachably connected to each other. Figures 2 and 4 show the megawatt DC contact pin 110 in its assembled state, in which the outer part 111 is attached to the inner part 112. Fig. 3 shows the megawatt DC contact pin 110 in a disassembled state, with the outer part 111 separated from the inner part 112. The inner part 112 is the part that faces the interior of the housing 2. The outer part 111 is the part that faces outwards, away from the housing 2. The outer part 111 is also the part that comes into mechanical contact when connected to a high-power connector. This can lead to wear on the outer part 111. Therefore, the outer part 111 and the inner part 112 are designed to be separable from one another, allowing the outer part 111 to be replaced. For this purpose, the outer part 111 and the inner part 112 each have a connecting device 113a and 113b, respectively. The connecting devices 113a and 113b, which can be seen particularly in Fig. 3, together form a bayonet fitting. The outer part 111 is inserted into the inner part 112 and secured by rotating it around the indicated axis of rotation. As can be seen in the cross-section shown in Fig. 4, the inner part 112, except for the area that receives the outer part 111, i.e., the connecting element 113b, is made of solid material. The outer part 111, on the other hand, is entirely hollow. This allows part of the high-voltage connector to be inserted into the outer part 111. As can be seen particularly in Fig. 2, the inner part 112 is rotationally asymmetric and has a plate-shaped area 114, designated by reference numeral 114 in Fig. 3. In contrast, the outer part 111 is rotationally symmetric. In this case, the outer part 111 is in particular pin-shaped. Since the inner part 112 is aligned with the housing 2 of the high-voltage distribution unit 1, it is advantageous if the only sealing seats 116 are formed in this part. Here, the sealing seat 116 is formed from a shoulder 115 and an annular groove area adjacent to the shoulder 115. The sealing seat 116 is thus designed in particular to receive an annular seal. As can be seen in particular in Fig. 4, the outer part 111 has a tool receptacle 117 on an upper area or an outwardly pointing area with respect to the high-voltage distribution unit 1 or the connection element 100. The tool holder 117 is incorporated into the outer part 111, so that a tool for rotating the outer part 111 relative to the inner part 112 is inserted into the outer part 111. Accordingly, the contact area for the tool is located within the outer part 111. Reference sign 1 High-voltage distribution unit 2 Housing 2a Wall 3 High-voltage components 10 High-performance connector 100 Connection element 110a Contact pin receptacles 110 Contact pins 111 Outer part 112 Inner part 113a Connection device 113b Complementary connection device 114 Plate-shaped area 115 Shoulder 116 Seal seat 117 Tool holder 120a Contact pin receptacle 120 Contact pin 130a Contact pin receptacle 130 Contact pin 140a Contact pin receptacle 140 Contact pin 150a Contact pin receptacle 150 Contact pin 200 Collar

Claims

High-performance connector (10) for megawatt coupling, in particular for an electric vehicle, comprising: a connector element (100) with a plurality of contact pin receptacles (110a, 120a, 130a, 140a, 150a) and associated contact pins (110, 120, 130, 140, 150); a circumferential collar (200) formed around the connector element (100) and laterally surrounding the connector element (100), wherein the plurality of contact pin receptacles (110a, 120a, 130a, 140a, 150a) comprises two DC contact pin receptacles (110a), characterized in that each of the two DC contact pin receptacles (110a) contains a megawatt DC contact pin (110) which is formed in two parts, wherein the The megawatt direct current contact pin (110) has an outer part (111) and an inner part (112) which is detachably connected axially to the outer part (111). High-performance connector (10) according to claim 1, characterized in that the outer part (111) has a connecting device (113a) and the inner part (112) has a complementary connecting device (113b), wherein the connecting device (113a) and the complementary connecting device (113b) are preferably designed as a rotatable connection and in particular as a bayonet lock. High-performance connector (10) according to one of claims 1 or 2, characterized in that a sealing seat (116), preferably the only one, is formed on the inner part (112). High-performance connector (100) according to one of the preceding claims, characterized in that the inner part (112) and the outer part (111) are made of different materials. High-performance connector (100) according to one of the preceding claims, characterized in that the inner part (112) is formed at least substantially from a solid material. High-performance connector (100) according to one of the preceding claims, characterized in that the outer part (113) is preferably designed entirely as a hollow body. High-performance connector (100) according to one of the preceding claims, characterized in that the inner part (112) is rotationally asymmetric and preferably has a plate-shaped area (114). High-performance connector (100) according to one of the preceding claims, characterized in that the outer part (111) is rotationally symmetrical and in particular is pin-shaped. High-performance connector (10) according to one of the preceding claims, characterized in that a tool receptacle (117) for receiving a tool for rotating and loosening or fastening the outer part (111) relative to the inner part (112) is formed on an upper area in the outer part (111). High-voltage distribution unit (1) for energy distribution and / or energy conversion and / or energy protection in a vehicle, wherein the high-voltage distribution unit (1) comprises: several high-voltage components (3) which are operated by means of high voltage, wherein the high-voltage components (3) preferably comprise at least several high-voltage busbars and high-voltage switching devices for switching on or off individual high-voltage busbars, a housing enclosing the high-voltage components (3), wherein the housing (2) has a wall (2a), and a high-performance connector (10) according to one of the preceding claims.

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