Modular contactor box

Abstract

The invention relates to a modular contactor box, in particular for electric vehicles. The object of the invention is to provide a concept with which the required number of contactors can be achieved at low cost and with low space requirements. According to the invention, this object is achieved in that the modular contactor box comprises a module housing with a plurality of plug-in points for receiving a respective contactor module, at least two contactor modules with a respective at least two contactor module connection contacts, wherein each contactor module is accommodated in one of the plug-in points of the module housing, and at least two contactor box connection contacts, wherein at least two of the contactor modules are connected internally with one another in such a way that the maximum number of contactor box connection contacts is lower than the number of contactor module connection contacts by at least 1.

Description

[0001] Modular contactor box

[0002] The present invention relates to a modular contactor box, in particular for electric vehicles.

[0003] Current climate and environmental protection goals can only be achieved if road transport also makes a significant contribution. A key component of this is the increasing trend toward electric drives in all vehicle classes. This affects all areas, from private transport and local public transport to commercial transport and goods transport. In goods transport, electric vehicles offer not only the most important aspect of environmentally friendly driving, but also other compelling advantages: For example, the drive system of an electric vehicle requires significantly less maintenance and its service life is noticeably longer than that of conventionally powered vehicles. This results in significantly higher efficiency, especially in short- and medium-distance travel.

[0004] Electric vehicles are powered by an electric motor that draws its energy from a high-capacity battery pack. The battery pack is charged at charging stations. To ensure safe connection and disconnection of the battery pack to both the electric vehicle's drive system and a charging station, each electric vehicle is equipped with a power system with multiple contactors. Depending on the application, 5 to 9 contactors may be required. This results in increased space requirements and thus increased costs.

[0005] The object of the present invention is therefore to provide a concept with which the required number of contactors can be realized with the required safety while at the same time reducing costs and space requirements.

[0006] For this purpose, according to the invention, a modularly constructed contactor box is provided, comprising a module housing with a plurality of receiving locations for receiving one contactor module each, at least two contactor modules each with at least two contactor module connection contacts, wherein each contactor module is received in one of the receiving locations of the module housing, and at least two contactor box connection contacts, wherein at least two of the contactor modules are internally interconnected in such a way that the number of contactor box connection contacts is at least 1 less than the number of contactor module connection contacts.

[0007] A "modular contactor box" means that the contactor box is constructed in a modular fashion. This means that the required components, in particular a plurality of contactor modules, are provided. These may be of similar design, but may also differ from one another depending on the required application. From this number of similar or different components, in particular contactor modules, the required components / contactor modules are selected depending on the application.

[0008] The module housing has a plurality of mounting locations into which the required contactor modules can be easily inserted. Preferably, the external dimensions of the contactor modules are identical, and the mounting locations are then also identical. However, contactor modules with different external dimensions can also be provided, and the mounting locations in the module housing are then adapted accordingly. This results in a simple design and therefore easy assembly of the contactor box. Because the contactor modules are as identical as possible in their external dimensions, identical parts can be used, with the associated potential for cost savings. Advantageously, the contactor modules are prefabricated or existing units that can be easily installed.Integrating the contactor modules into the contactor box saves installation space, which also leads to cost reductions. However, adaptations to customer-specific requirements are possible.

[0009] The contactor module connection contacts are the connection contacts of a contactor module with which the contactor module is connected to the line to be interrupted. Furthermore, each contactor module also has switching contacts, preferably at least one movable contact and one fixed contact. The contactor box connection contacts are the connection contacts that lead out of the module housing of the contactor box and enable the components of the contactor box to be connected to external lines. Since at least two of the contactor modules are internally connected to one another, so that the number of contactor box connection contacts is at least one less than the number of contactor module connection contacts, additional electrical connections with connecting conductors, e.g., screw connections, are no longer necessary. This enables a reduction in electrical losses.If more than two contactor modules are internally connected, the number of contactor box connection contacts is correspondingly lower. The contactor module connection contacts can be integrated into the contactor box connection contacts or formed integrally with them.

[0010] Advantageous embodiments of the present invention are the subject of the dependent claims. In one advantageous embodiment, it can be provided that the internally interconnected contactor modules are interconnected via a common connecting element forming the contactor module connection contacts. The connecting element preferably also forms a contactor box connection contact. The connecting element can, for example, be designed as a busbar, thus as a metallic sheet or rail made of copper or aluminum. This enables a simple and robust design. Furthermore, the fixed contacts of the contactor modules can also be formed on the busbar. Since the contactor modules are internally interconnected, an additional contact point in the system is saved. This leads to a reduction in the contact resistance.

[0011] In a further embodiment, more than two contactor modules can be interconnected internally, preferably by means of a common connecting element designed as a multiple bridge. This eliminates the need for additional contact points in the system, with the advantages described above.

[0012] Advantageously, the contactor modules can be inserted into the receptacles. The receptacles are then designed as plug-in locations, so that the contactor modules can be easily inserted into the slots during assembly. Preferably, the contactor modules can also be latched or secured in the slots.

[0013] A further advantageous embodiment can provide that each contactor module has at least one movable contact and at least one fixed contact, and the at least one fixed contact of at least one contactor module has grooves running transversely to a closing direction of the contacts of the at least one contactor module, wherein the groove flanks of the grooves run at least partially obliquely with respect to the closing direction, so that the groove flanks have an angle of magnitude not equal to 90° to the closing direction, and wherein the at least one movable contact of the at least one contactor module is designed such that the contact existing in the closed position of the contacts of the at least one contactor module between the fixed contacts and the movable contacts is established on the obliquely running groove flanks.This eliminates the need for additional contact, resulting in reduced material, weight, and volume, as well as reduced contact resistance. Furthermore, short-circuit strength is increased.

[0014] Further space savings can be achieved by incorporating at least one extinguishing zone in the module housing to extinguish arcs generated during a switching operation of the contactor modules. Advantageously, the at least one extinguishing zone can be assigned to at least two contactor modules. These contactor modules do not switch simultaneously. By using the extinguishing zone for two or more contactor modules, further optimization of the installation space is achieved.

[0015] In a further advantageous embodiment, at least one fuse can be arranged in the module housing. Integrating an additional component into the contactor box further simplifies installation in the vehicle and optimizes space requirements.

[0016] This can also be achieved by arranging at least one pyroelectric switch in the module housing. These designs also increase safety.

[0017] Further simplification of assembly can be achieved by the contactor box further comprising at least one plug interface and / or sensors for current measurement being arranged in the module housing and / or tapping points for voltage measurement being arranged in the module housing.

[0018] According to yet another variant, at least one of the contactor modules can have at least one fixed contact and at least one movable contact, as well as a coil for driving the at least one movable contact. The coil has coil terminals, and all coil terminals are arranged on the module housing and can be contacted together. The coils of the contactor modules can be controlled individually. This also leads to cost savings in terms of the parts used and during assembly. Advantageously, the coil terminals can be controlled via a circuit board or a lead frame.

[0019] Yet another advantageous embodiment can provide for the contactor box to include a common control module arranged on the module housing. The control module can be installed at various locations and enables joint control of the components arranged in the contactor box.

[0020] Embodiments of the present invention are explained in more detail below with reference to drawings.

[0021] They show:

[0022] Figure 1: schematic representation of the electrical connections of batteries in an electric vehicle, Figure 2: schematic representation according to Fig. 1 in ferry operation of the electric vehicle,

[0023] Figure 3: schematic representation according to Fig. 1 when charging the electric vehicle with

[0024] 800 V,

[0025] Figure 4: schematic representation according to Fig. 1 when charging the electric vehicle with 400 V,

[0026] Figure 5: schematic representation of a modular contactor box for an electric vehicle,

[0027] Figure 6: Module housing of the contactor box from Fig. 5,

[0028] Figure 7: a contactor module of the contactor box from Fig. 5, and

[0029] Figure 8: Top view of the contactor box from Fig. 5.

[0030] In the following explanations, identical parts are designated by identical reference numerals. Where a figure contains reference numerals that are not further explained in the corresponding figure description, reference is made to preceding or subsequent figure descriptions.

[0031] In an electric vehicle, contactors are necessary to charge the battery at different networks or charging stations or to couple it to the electric motor. Fig. 1 shows a schematic representation of possible electrical connections of the batteries 1 in an electric vehicle. The electric vehicle comprises two batteries 1. The batteries 1 can be connected to the drive or the motor of the electric vehicle via vehicle connections 2, 3. Vehicle connecting lines 4 are provided between the batteries 1 and the vehicle connections 2, 3. Three main contactors 5 are arranged in the vehicle connecting lines 4. Furthermore, the batteries 1 can be connected to charging connections 7, 8 via charging connection lines 6. The charging connection lines 6 contain two first charging contactors 9 for charging the batteries with 800 V and two second charging contactors 10 for charging the batteries with 400 V.In addition, fuses 11 and / or pyro switches 12 can be arranged in the charging connection lines 6 and / or in the vehicle connection lines 4.

[0032] Fig. 2 shows the electrical connections of the batteries 1 when the electric vehicle is in operation. In this state, the batteries 1 are connected to the vehicle terminals 2, 3. The three main contactors 5 arranged in the vehicle connection lines 4 are therefore closed, allowing the batteries 1 to supply the electric vehicle or its drive with power. The first charging contactors 9 and the second charging contactors 10 are open.

[0033] Fig. 3 shows a first charge state of the batteries 1. In this case, the batteries 1 are electrically connected to the charging terminals 7, 8 via the charging connection lines 6. For this purpose, both the first charging contactors 9 and the main contactor 5 arranged between the two batteries 1 are closed. The second charging contactors 10 are open, as are the two main contactors 5 leading to the vehicle terminals 2, 3. The batteries 1 are thus connected to the charging station in series. This enables the batteries 1 of the electric vehicle to be charged at 800 V.

[0034] A second option for charging the electric vehicle's batteries 1 is shown in Fig. 4. There, both the first charging contactors 9 and the second charging contactors 10 are closed. All three main contactors 5 are open. The batteries 1 are thus connected to the charging station in a parallel circuit. This allows the electric vehicle's batteries 1 to be charged at 400 V.

[0035] As can be seen from Figures 1 to 4, several contactors are required in an electric vehicle to enable charging of the batteries 1 at different networks or charging stations, or to connect the batteries to the drive of the electric vehicle, i.e., the electric motor. Figures 1 to 4 show seven contactors: the three main contactors 5, the two first charging contactors 9, and the two second charging contactors 10. In other applications, more or fewer contactors, for example, five to nine contactors, may be provided.

[0036] In order to save installation space and simplify assembly, the contactors of the electric vehicle, i.e. the main contactors 5, the first charging contactors 9 and the second charging contactors 10, are each designed as a contactor module that is arranged in a modular contactor box 13. The modular contactor box 13 is shown in Fig. 5. The term contactor module means that the contactors are constructed as identically as possible or contain as many of the same components as possible, so that cost-effective production is possible. Depending on the application, the required contactor modules are selected and inserted into the modular contactor box 13. For this purpose, the modular contactor box 13 comprises a module housing 14. The module housing 14 is described in more detail below with reference to Fig. 6. The contactor modules are inserted in the module housing 14.In order to minimize electrical losses, installation space requirements and costs, at least two of the contactor modules arranged in the contactor box are interconnected internally, i.e. in the contactor box 13. This is described in more detail below with reference to Figures 6 to 8. Each of the contactor modules has at least two contactor module connection contacts. The contactor module connection contacts are the contacts of each contactor module with which it is connected to the line to be interrupted. At least one of the contactor modules has an electromagnetic drive, preferably a coil. Each coil is provided with coil connections 16. The coil connections 16 are led out through the module housing 14 and can be jointly contacted via a circuit board / lead grid 17. The coils of the individual contactor modules can be controlled individually. A contactor box connection contact 18 is also shown in Fig. 5.The modular contactor box 13 can also have multiple contactor box connection contacts, whereby the maximum number of contactor box connection contacts is always at least 1 less than the number of contactor module connection contacts of all contactor modules arranged in the contactor box. Furthermore, the modular contactor box 13 can comprise a control assembly 15 attached to the module housing 14. Fig. 5 shows three possible installation positions for the control assembly 15. For example, the control assembly 15 can be arranged on one of the side walls of the module housing 14. However, it would also be conceivable for the control assembly to be attached to the circuit board / lead frame 17.

[0037] Fig. 6 shows the module housing 14 of the modular contactor box 13 from Fig. 5. The module housing 14 is designed as a compartment housing. This means that the module housing 14 has a plurality of compartments or receiving locations 19. Fig. 6 shows eight receiving locations 19. Each of the receiving locations 19 is designed such that a contactor module can be easily inserted and advantageously also locked into place.

[0038] Fig. 7 shows, by way of example, a contactor module 20 of the modular contactor box 13 from Fig. 5. Preferably, at least the external dimensions of all contactor modules 20 that can be inserted into the contactor box 13 are identical. However, it can also be provided that a majority or all of the contactor modules 20 are completely identical in construction. Each of the contactor modules 20 has a contactor housing 21. The contactor housing 21 and the receiving locations 19 of the module housing 14 are coordinated with one another, so that each of the contactor housings 21 can be easily inserted, preferably plugged, into each of the receiving locations 19 of the module housing 14.

[0039] An electromagnetic drive with a coil 22 is arranged in the contactor housing 21. A contact bridge 23 can be moved by means of the electromagnetic drive. Two movable contacts 24 are formed on the contact bridge 23. Each of the movable contacts 24 interacts with a fixed contact. Each of the fixed contacts is connected to a contactor module connection contact. It can also be provided that the fixed contacts are formed on the contactor module connection contact or are integrally connected to it (not shown).

[0040] Fig. 8 shows a top view of the module housing 14 with contactor modules 20 arranged therein. As already described, the module housing 14 has eight receptacles 19, each for accommodating a contactor module 20. A contactor module 20 is plugged into six of the receptacles 19. Two receptacles 19 are empty. The contactor modules 20 are designed according to the embodiment shown in Fig. 7. In addition, each contactor module 20 has two fixed contacts that interact with the two movable contacts 24 arranged on the contact bridge 23.

[0041] As clearly visible in Fig. 8, two of the contactor modules 20 are interconnected internally, i.e., in the contactor box 13. Connecting elements 25 are provided for this purpose, with two fixed contacts formed on each of the connecting elements 25, and these two fixed contacts are assigned to two different contactor modules 20. The connecting elements 25 form a contactor module connection contact for each of the contactor modules 20 that they interconnect. If a connecting element interconnects two contactor modules, this connecting element forms two contactor module connection contacts.

[0042] The connecting elements 25 can be designed as a busbar. In addition, each of the connecting elements 25 has an outward-facing contactor box connection contact 18. The contactor box connection contacts 18 can be designed as a connection tab or as a contact pill 26. The other fixed contact of the respective contactor module 20 is also formed on a busbar and forms a contactor module connection contact. In the case shown in Fig. 8, the contactor module connection contacts that are not formed on the connecting elements 25 are integrated into contactor box connection contacts 18, wherein the contactor box connection contacts 18 have a contact pill 26 that leads out of the module housing 14 and enables an external connection. As can be seen in Fig. 8, the two upper connecting elements 25 are approximately Z-shaped. The contactor box connection contacts 18 shown in Fig.8 The connecting element 25 located below is F-shaped and bridges an underlying fixed contact / busbar. It is also possible for the connecting elements to be designed as a multiple bridge and to connect more than two contactor modules to one another. The fixed contacts of at least one of the contactor modules can have grooves running transversely to a closing direction of the contacts of the contactor modules, wherein the groove flanks of the grooves run at least partially obliquely with respect to the closing direction, so that the groove flanks have an angle of magnitude other than 90° to the closing direction, and wherein the movable contacts of the contactor modules are designed such that the contact existing between the fixed contacts and the movable contacts in the closed position of the contacts of the contactor modules is established at the obliquely running groove flanks.

[0043] Furthermore, it can be provided that the fuses or pyro switches shown in Figures 1 to 4 are integrated into the contactor box, that the contactor box comprises a plug interface and that sensors for current measurement and tapping points for voltage measurement are arranged in the module housing

[0044] In addition, at least one extinguishing zone can be formed in the module housing to extinguish arcs generated during a switching operation of the contactor modules. Since the pressure drop when switching off the contactor modules occurs relatively quickly according to Paschen's law, a small-volume extinguishing zone may be sufficient. This reduces the installation space. To further reduce the volume of the contactor box, the extinguishing zone can be assigned to at least two contactor modules.

[0045] List of reference symbols

[0046] 1 battery

[0047] 2.3 Vehicle connection

[0048] 4 Vehicle connection line

[0049] 5 Main contactor

[0050] 6 Charging connection cable

[0051] 7, 8 charging ports

[0052] 9 first charging contactors

[0053] 10 second charging contactors

[0054] 11 fuses

[0055] 12 pyro switches

[0056] 13 Contactor box

[0057] 14 module housings

[0058] 15 Control module

[0059] 16 coil connections

[0060] 17 Circuit board / lead grid

[0061] 18 connection contacts

[0062] 19 slots

[0063] 20 contactor module

[0064] 21 contactor housing

[0065] 22 coil

[0066] 23 Contact bridge

[0067] 24 movable contacts

[0068] 25 fasteners

[0069] 26 Contact pill

Claims

Claims: Modularly constructed contactor box (13), particularly for electric vehicles, comprising: a module housing (14) with a plurality of mounting positions (19) for receiving one contactor module (20) each, at least two contactor modules (20) each with at least two contactor module connection contacts, wherein each contactor module (20) is received in one of the mounting positions (19) of the module housing (14), and at least two contactor box connection contacts (18), wherein at least two of the contactor modules (20) are internally interconnected such that the maximum number of contactor box connection contacts (18) is at least 1 less than the number of contactor module connection contacts. Contactor box (13) according to claim 1, characterized in that the internally interconnected contactor modules (20) are interconnected via a common connecting element (25) forming the fixed contacts.A contactor box according to at least one of the preceding claims, characterized in that more than two contactor modules are internally interconnected, preferably by means of a common connecting element designed as a multiple bridge. A contactor box (13) according to at least one of the preceding claims, characterized in that the contactor modules (20) can be plugged into the mounting positions (19).Contactor box (13) according to at least one of the preceding claims, characterized in that each contactor module (20) has at least one movable contact and at least one fixed contact, and the at least one fixed contact of at least one contactor module (20) has grooves extending transversely to a closing direction of the contacts of the at least one contactor module (20), wherein the groove flanks of the grooves extend at least partially inclined with respect to the closing direction, such that the groove flanks have an angle of non-90° to the closing direction, and wherein the at least one movable contact (24) of the at least one contactor module (20) The module is designed such that the contact existing in the closed position of the contacts of the at least one contactor module (20) is established between the fixed contacts and the movable contacts on the inclined groove flanks. A contactor box (13) according to at least one of the preceding claims, characterized in that at least one arc suppression zone is formed in the module housing (14) for extinguishing arcs generated during a switching operation of the contactor modules (20). A contactor box (13) according to claim 6, characterized in that the at least one arc suppression zone is assigned to at least two contactor modules (20). A contactor box (13) according to at least one of the preceding claims, characterized in that at least one fuse is arranged in the module housing (14).A contactor box (13) according to at least one of the preceding claims, characterized in that at least one pyrolytic switch is arranged in the module housing (14). A contactor box (13) according to at least one of the preceding claims, further comprising a connector interface. A contactor box (13) according to at least one of the preceding claims, characterized in that sensors for current measurement are arranged in the module housing. A contactor box (13) according to at least one of the preceding claims, characterized in that tap points for voltage measurement are arranged in the module housing.A contactor box (13) according to at least one of the preceding claims, characterized in that at least one of the contactor modules (20) has a coil (22) for driving the movable contacts (24), wherein the coil (22) has coil connections (16) and all coil connections (16) are arranged on the module housing (14) and can be contacted together. A contactor box (13) according to at least one of the preceding claims, further comprising a common control assembly (15) arranged on the module housing (14).

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