Device for producing an electric connection between a high-voltage line and a high voltage component

Abstract

The invention relates to a device (100) for producing an electric connection between a high-voltage line and a high voltage component (50), comprising a housing (52) which at least comprises a plug connector (10) that has at least one pin trough housing (12) and at least one contact pin (14, 16). The plug connector (10), the at least one pin trough housing (12), and the at least one contact pin (14, 16) are arranged on the housing (52) so as to be nondestructively replaceable from the outside.

Description

[0001] Device for establishing an electrical connection between a high-voltage cable and a high-voltage component

[0002] The invention relates to a device for establishing an electrical connection between a high-voltage line and a high-voltage component.

[0003] To connect different components of a high-voltage system, cables are usually used which are connected to the pin trays of the components using connectors.

[0004] DE 102019 132 599 A1 discloses a holding arrangement for a line element designed to transmit electrical energy on a housing of a motor vehicle. The line element has an electrical conductor for transmitting the electrical energy and a sheath that encloses at least a length of the conductor and electrically insulates the conductor. A connecting element formed separately from the line element is secured to the line element. The connecting element has a flange arranged on a first side of a wall of the housing, via which the connecting element and, via the flange, the line element are fastened to the housing. At least the conductor extends through a first through-opening of the flange and through a second through-opening of the housing.

[0005] DE 102018 202 955 A1 further discloses a connector system comprising a connector and a housing on which the connector is mounted. The housing has an opening with a first inner wall. The connector has a shielding plate, which protrudes at least partially into the opening. A ring is arranged in the opening and, with an outer wall, electrically contacts the first inner wall of the opening. The shielding plate, with a further outer wall of the shielding plate, electrically contacts a second inner wall of the ring.DE 102020 123476 A1 discloses a socket with a first plug face for connecting a plug and with a second plug face with at least one contact assembly that can be fastened or detachably fastened thereto, which has at least one contact element and / or via which the electrical energy and / or the electrical signals can be transmitted by means of at least one electrical line.

[0006] An object of the invention is to provide a device for establishing an electrical connection between a high-voltage line and a high-voltage component, which is easily replaceable.

[0007] The above-mentioned object is solved by the features of independent claim 1.

[0008] Advantageous embodiments and advantages of the invention emerge from the further claims, the description and the drawing.

[0009] According to one aspect of the invention, a device for establishing an electrical connection between a high-voltage cable and a high-voltage component is provided with a housing, comprising at least one plug connector, which has at least one pin housing and at least one contact pin. The plug connector, the at least one pin housing, and the at least one contact pin are arranged on the housing in a manner that allows them to be replaced from the outside without causing any damage.

[0010] Advantageously, the proposed device for establishing an electrical connection between a high-voltage cable and a high-voltage component is accessible from outside the high-voltage component and can be attached to the high-voltage component from the outside, and thus also replaced. The mechanical and electrical connection of at least one contact pin to the busbars of the high-voltage component is also possible from outside the high-voltage component.

[0011] For this purpose, the connector is arranged on an outer side of the housing of the high-voltage component in a manner that is detachable, in particular replaceable, from the outside. The connector has a pin-tub housing for receiving a mating connector of the high-voltage cable. The pin-tub housing is arranged on an opening in the housing in a manner that is detachable, in particular replaceable, from the outside. The connector further has at least one contact pin for establishing an electrical connection to the mating connector and for mechanically and electrically connecting to busbars of the high-voltage component inside the housing, which contact pins are arranged on the housing in a manner that is detachable, in particular replaceable, from the outside.

[0012] If the device needs to be repaired, the pin tray housing can be repaired without having to disassemble the high-voltage component or, depending on the fault and design, without having to re-test the leak tightness.

[0013] There is no need to provide access to the pin tray inside the high-voltage component, since at least one contact pin is screwed to the busbars from the outside and therefore no screws are required to contact the at least one contact pin inside.

[0014] The design flexibility for possible positions of the pin tray is increasing, enabling more favorable arrangements of the connections and more efficient use of the installation space in high-voltage batteries for range-relevant cells.

[0015] The device for establishing a plug connection between a high-voltage cable and the high-voltage component can be arranged on the housing of the high-voltage component by first bringing the pin tray housing up to the opening of the housing. Subsequently, at least one contact pin of the pin tray housing is screwed to busbars inside the housing. The pin tray housing is then screwed to the housing of the high-voltage component.

[0016] In a favorable embodiment, the pin tray housing can remain installed during a repair of the high-voltage component. In the event of a defect in a contact of the pin tray, the at least one contact pin can be replaced individually. Since no sealing components are replaced, a final leak test of the high-voltage component after replacement is not necessary. Radial and surface contacts can be used on the at least one contact pin.

[0017] In another advantageous embodiment, both round and square contact pins can be used. Furthermore, larger tolerances are possible in the manufacturing of the individual components of the device.

[0018] The pin tray housing can advantageously be designed for screw connection to the housing of the high-voltage component. This allows for flexible installation and possible replacement of the pin tray housing in the event of repair. Advantageously, the pin tray housing can have a sealing element for sealing the housing of the high-voltage component, which encloses the opening when properly installed on the housing. In this way, the pin tray housing can be securely sealed to the housing of the high-voltage component.

[0019] According to an advantageous embodiment of the device, the at least one contact pin can be screwed or screwable to the busbars of the high-voltage component. In this way, the at least one contact pin can be connected to the busbars from outside the housing of the high-voltage component and can also be conveniently replaced in the event of repair.

[0020] According to an advantageous embodiment of the device, the pin tray housing can have alignment elements that, when properly installed, protrude into the interior of the housing and are designed to connect to corresponding mating elements of the busbars. This allows the busbars to be conveniently positioned for assembly by aligning them with the aid of the pin tray housing. The at least one contact pin can be conveniently connected to the busbars after inserting the alignment elements of the pin tray housing into the corresponding mating elements of the busbars.

[0021] According to an advantageous embodiment of the device, the at least one contact pin can have a thread, in particular an external thread, for connection to the busbars at an end facing away from a plug-in contact surface. In this way, the at least one contact pin can be conveniently positioned from outside the housing at connection points of the busbars, for example, screw holes, and screwed to the busbars. This ensures permanent contact between the at least one contact pin and the busbars.

[0022] According to an advantageous embodiment of the device, the at least one contact pin can have a threading aid on the thread for alignment with an internal thread of the busbars. In this way, the at least one contact pin can be positioned even more easily from outside the housing at connection points of the busbars, for example screw holes, and screwed to the busbars. This ensures permanent contact between the at least one contact pin and the busbars. According to an advantageous embodiment of the device, the at least one contact pin can be surrounded by an insulating body as contact protection, which has the geometric shape of a standard drive on its outer side. In particular, the at least one contact pin can be embedded in the insulating body. The standard drive can, for example, have the geometry of an external hexagon or a multi-tooth drive.This standard drive allows at least one contact pin to be screwed directly into the threads of the busbars from the outside via openings provided for this purpose in the pin tray housing.

[0023] According to an advantageous embodiment of the device, the insulating body can have a circumferential electrical shield, in particular a metallic spring contact. The shield can be designed for electrical contact with the housing of the high-voltage component, in particular via spring contacts, when properly mounted on the housing. In this way, the electrical shielding can advantageously be transferred from the plug connection to the component housing.

[0024] According to an advantageous embodiment of the device, the at least one contact pin can be arranged in a contact carrier which is arranged in the pin socket housing so as to be movable at least in one plug-in direction. In this way, the at least one contact pin can be positioned relative to the busbars and screwed to them. In an application with at least two contact pins, the contact pins can advantageously be positioned additionally relative to one another in this way. This also allows for larger tolerances in the manufacture of the pin socket housing. Advantageously, the contact carrier in which the at least one contact pin is arranged can be aligned in one plug-in direction when screwing the at least one contact pin to the busbars. Conveniently, the at least one contact pin can be designed as a radial contact or as a clamp contact.

[0025] According to an advantageous embodiment of the device, the at least one contact pin can have a through-bore in its longitudinal extension, which is provided to accommodate a screw for screwing the at least one contact pin to the busbars during proper assembly. In particular, a screw head of the screw can comprise an insulating material as contact protection. The at least one contact pin can be reliably screwed to the busbars in this way. According to an advantageous embodiment of the device, the screwing of the at least one contact pin to the busbars can take place via an internal thread formed in the busbars or via a threaded bushing arranged on the busbars. To allow larger manufacturing tolerances, the threaded bushing can be designed, for example, as a movably mounted cage nut.At least one contact pin can thus be securely screwed to the busbars from outside the housing of the high-voltage component and allows reliable contact from the outside.

[0026] Advantageously, a connection for a high-voltage interlock cable of the high-voltage component can be designed as a plug-in connection in the pin tray housing, if necessary. The connection can conveniently be made from the rear of the pin tray. After the device has been brought close to the opening in the housing, the high-voltage interlock cable can be plugged into the pin tray housing. The internal cable harness in the component can advantageously have a slight excess length for this purpose, so that it can be plugged in before the pin tray is installed, and the excess cable harness can be pushed back into the component housing during the installation of the pin tray.

[0027] Further advantages will become apparent from the following description of the drawings. The drawings illustrate an exemplary embodiment of the invention. The drawings, the description, and the claims contain numerous features in combination. Those skilled in the art will also expediently consider the features individually and combine them into useful further combinations.

[0028] Showing:

[0029] Fig. 1 shows a schematic section through a high-voltage component with a device for establishing an electrical connection between a high-voltage line and the high-voltage component according to an embodiment of the invention;

[0030] Fig. 2 shows a section through a contact pin of the device according to Figure 1 with an insulating body; and

[0031] Fig. 3 shows a schematic section through a high-voltage component with a device for establishing an electrical connection between a high-voltage line and the high-voltage component according to a further embodiment of the invention.

[0032] In the figures, identical or similar components are numbered with the same reference numerals. The figures show only examples and are not to be understood as limiting.

[0033] Figure 1 shows a schematic section through a high-voltage component 50 with a device 100 for establishing an electrical connection between a high-voltage line and the high-voltage component 50 according to an embodiment of the invention.

[0034] The device 100 comprises a connector 10, which has at least one pin tray housing 12 and two contact pins 14, 16. The connector 10, the at least one pin tray housing 12, and the two contact pins 14, 16 are arranged on the housing 52 of the high-voltage component 50 in a manner that allows them to be replaced from the outside without causing any damage.

[0035] The plug connector 10 is arranged detachably, in particular replaceably, from the outside on an outer side 56 of the housing 52 of the high-voltage component 50. The plug connector 10 has a pin tray housing 12 for receiving a mating connector of the high-voltage cable. The pin tray housing 12 is arranged detachably from the outside on an opening 54 of the housing 52. The plug connector 10 further has two contact pins 14, 16 for establishing an electrical connection to the mating connector and for mechanically and electrically connecting to busbars 60, 62 of the high-voltage component 50 in the interior 58 of the housing 52, which contact pins are arranged detachably, in particular replaceably, from the outside on the housing 52. For this purpose, the two contact pins 14, 16 can be screwed to the busbars 60, 62 of the high-voltage component 50, for example.

[0036] A plugging direction 40 of the mating connector into the connector 10 is indicated by an arrow. The busbars 60, 62, which are connected to the contact pins 14, 16 of the high-voltage component 50 inside 58 of the housing 52, can advantageously be designed as a single piece or at least as a continuous piece. For this purpose, the busbars 60, 62 can, for example, be jointly overmolded with plastic or aligned with one another in a common holder 72. Instead of holes for threading screws through, threads can be provided in the busbars 60, 62. The thread can, for example, be designed as a threaded insert, pull-through, rivet nut, weld nut, or, with sufficient material thickness, as a cut or formed thread directly in the busbar 60, 62.

[0037] The busbars 60, 62 can be pre-aligned via their screw connection to the housing 52.

[0038] Advantageously, a connection for a high-voltage interlock cable of the high-voltage component 50 can, if necessary, be designed as a plug connection in the pin-head housing 12. The connection can expediently be made from the rear of the connector 10. After the device has been brought up to the opening 54 of the housing 52, the high-voltage interlock cable can be plugged into the pin-head housing 12. The internal cable harness in the component 50 can advantageously have a slight excess length for this purpose, so that it can be plugged in before the connector 10 is installed, and the excess cable harness can be pushed back into the component housing 52 during the installation of the connector 10.

[0039] The pin tray housing 12 can be screwed to the housing 52 of the high-voltage component 50, for example, using several screws. Furthermore, the pin tray housing 12 has a sealing element 18 for sealing the housing 52, which, when properly installed on the housing 52, encloses the opening 54. The connector on the cable harness then seals the pin tray housing 12 and seals the high-voltage component 50.

[0040] The pin header housing 12 has alignment elements 20, 22, for example, molded-on pins, which, when properly assembled, protrude into the interior 58 of the housing 52 and can be connected to corresponding mating elements 64, 66 of the busbars 60, 62. The busbars 60, 62 can be aligned by inserting the alignment elements 20, 22 of the pin header housing 12 into these mating elements 64, 66 of the busbars 60, 62.

[0041] The distance between the contact pins 14, 16 can be adjusted via the distance between the threads in the busbars 60, 62. To keep tolerances as small as possible, the threads or thread core holes can be created by precise machining, for example, by CNC milling, which can advantageously be carried out after the two busbars have been precisely aligned with each other, for example, by overmolding. Figure 2 shows a section through a contact pin 14 of the device 100 with an insulating body 32.

[0042] The contact pins 14, 16 have a thread 28, in particular an external thread, for connection to the busbars 60, 62 at an end 26 facing away from a plug contact surface 24. In particular, the contact pins 14, 16, as can be seen in Figure 2, can have a threading aid 30 on the thread 28 for aligning the busbars 60, 62 into an internal thread 68.

[0043] The contact pins 14, 16 are each surrounded by an insulating body 32 as a contact protection, which has a geometric shape 33 of a standard drive on its outside. Advantageously, the contact pins 14, 16 can be embedded in the insulating body 32. The standard drive can, for example, have the geometry of an external hexagon or a multi-tooth drive. This standard drive allows the contact pin 14, 16 to be screwed from the outside directly into the threads 68 of the busbars 60, 62 via openings provided for this purpose in the pin head housing.

[0044] The insulating body 32 has a circumferential electrical shield 34, which is designed in particular as a metallic spring contact 48. The shield 34 is designed for electrical contact with the housing 52 of the high-voltage component 50, in particular via spring contacts 48, when properly mounted on the housing 52. The circumferential spring contact 48 can be connected to the metallic component housing 52 via spring contacts 48 on the pin socket housing 12 when the contact pin 14, 16 is screwed in. In the case of shielded high-voltage cables, the cable shield can be contacted at this spring contact 48. In this way, the electrical shielding can be transferred from the connector to the component housing 52.

[0045] The device 100 can be arranged on the housing 52 of the high-voltage component 50 by bringing the pin tray housing 10 up to the opening 54 of the housing 52. The pin tray housing 12 can then be screwed to the housing 52. Subsequently, the two contact pins 14, 16 of the pin tray housing 12 are screwed to the busbars 60, 62 in the interior 58 of the housing 52.

[0046] In case of a defect in a contact of the connector 10, the contact pins

[0047] 14, 16 can be replaced individually. Since no sealing components are replaced, a final leak test of component 50 after replacement is not required. The contact pins 14, 16 can be designed as radial or surface contacts.

[0048] Figure 3 shows a schematic section through a high-voltage component 50 with a device 100 for establishing an electrical connection between a high-voltage line and the high-voltage component 50 according to a further embodiment of the invention.

[0049] In this exemplary embodiment, the connector 10 is designed as an assembly of at least two parts, namely a pin-header housing 12 and at least one contact carrier 36 mounted therein, movable in the plug-in direction 40, which are mounted together in a single step on the high-voltage component 50. A sealing element 18 is located on the pin-header housing 12, which seals off the component housing 52. The connector on the cable harness then seals off the pin-header housing 12 and seals the high-voltage component 50.

[0050] The two contact pins 14, 16 are arranged in the contact carrier 36, which is movable in the pin header housing 12 at least in one plug-in direction 40. The contact pins 14, 16 are very precisely aligned with each other in the contact carrier 36, for example, by being overmolded together with plastic.

[0051] The two contact pins 14, 16 can be designed, for example, as radial contacts or as clamp contacts.

[0052] The contact pins 14, 16 have a through-hole 38 along their longitudinal extension. The contact pins 14, 16 can be fastened to the busbars 60, 62 inside 58 of the component 50 via the through-holes 38 using at least one screw 42 each, thereby electrically connecting them. The contact carrier 36 is movably mounted in the pin header housing 12 in the plug-in direction 40 in order to compensate for positioning tolerances between the pin header housing 12 and the busbars 60, 62 in the plug-in direction 40 during the screwing of the contact pins 14, 16 to the busbars 60, 62 located behind them. By appropriately dimensioning the through-holes 38 in relation to the screw 42, it is possible to compensate for tolerances in the radial direction, for example, with regard to the position of the threads on the busbar surface.The contact carrier 36, in which the two contact pins 14, 16 are arranged, is aligned in the plug-in direction 40 when the contact pins 14, 16 are screwed to the busbars 60, 62. When the screw 42 is tightened, the contact pin 14, 16 is fixed in the plug-in direction 40.

[0053] The screw head 44 is insulated. The insulation serves as contact protection.

[0054] The screw connection of the contact pins 14, 16 to the busbars 60, 62 can be effected via an internal thread 68 formed in the busbars 60, 62 or, as can be seen in Figure 3, via a threaded bushing 70 arranged on the busbars 60, 62.

[0055] In this embodiment, round and square contact pins 14 and 16 can be implemented. Furthermore, simplified tolerance management is sufficient to meet the requirements of the connector.

[0056] List of reference symbols

[0057] 10 connectors

[0058] 12 pin tray housings

[0059] 14 contact pin

[0060] 16 contact pins

[0061] 18 Sealing element

[0062] 20 Alignment element

[0063] 22 Alignment element

[0064] 24 plug contact surface

[0065] 26 End

[0066] 28 threads

[0067] 30 Threading aid

[0068] 32 insulation bodies

[0069] 33 Geometric Shape

[0070] 34 umbrella

[0071] 36 contact carriers

[0072] 38 through hole

[0073] 40 Plug-in direction

[0074] 42 screw

[0075] 44 screw head

[0076] 48 spring contact (from shield 34)

[0077] 50 high-voltage components

[0078] 52 housings

[0079] 54 Opening

[0080] 56 Outside

[0081] 58 Interior (of the housing 52)

[0082] 60 busbar

[0083] 62 busbar

[0084] 64 Counter element

[0085] 66 Counter element

[0086] 68 internal thread

[0087] 70 threaded bushing

[0088] 72 holders

[0089] 74 Screw

[0090] 100 device

Claims

Patent claims Device (100) for establishing an electrical connection between a high-voltage line and a high-voltage component (50), having a housing (52) at least comprising a plug connector (10) having at least one pin tray housing (12) and at least one contact pin (14, 16), wherein the plug connector (10), the at least one pin tray housing (12), and the at least one contact pin (14, 16) are arranged on the housing (52) in a non-destructively replaceable manner from the outside. Device according to claim 1, wherein the at least one contact pin (14, 16) is screwed or can be screwed to busbars (60, 62) of the high-voltage component (50). Device according to claim 1 or 2, wherein the pin tray housing (12) has alignment elements (20, 22) which, when mounted as intended, protrude into the interior (58) of the housing (52) and are designed for connection to corresponding counter-elements (64, 66) of busbars (60, 62) of the high-voltage component (50).Device according to one of the preceding claims, wherein the at least one contact pin (14, 16) has a thread (28), in particular an external thread, for connection to busbars (60, 62) of the high-voltage component (50) on an end (26) facing away from a plug-in contact surface (24). Device according to claim 4, wherein the at least one contact pin (14, 16) has a threading aid (30) on the thread (28) for alignment with an internal thread (68) of the busbars (60, 62). Device according to one of the preceding claims, wherein the at least one contact pin (14, 16) is surrounded by an insulating body (32) as contact protection, which has a geometric shape (33) of a standard drive on its outer side, in particular wherein the at least one contact pin (14, 16) is embedded in the insulating body (32). Device according to claim 6, wherein the insulating body (32) has a circumferential electrical shield (34), in particular a metallic spring contact (48), wherein the shield (34) is designed for electrical contact with the housing (52) of the high-voltage component (50), in particular via spring contacts (48), when properly mounted on the housing (52). Device according to one of claims 1 to 2, wherein the at least one contact pin (14, 16) is arranged in a contact carrier (36) which is arranged in the pin socket housing (12) so as to be movable at least in one plug-in direction (40).Device according to claim 8, wherein the at least one contact pin (14, 16) has a through-bore (38) in its longitudinal extension, which is provided for receiving a screw (42) for screwing the at least one contact pin (14, 16) to busbars (60, 62) of the high-voltage component (50) during proper assembly, in particular wherein a screw head (44) of the screw (42) has an insulating material as contact protection. Device according to one of the preceding claims, wherein the screwing of the at least one contact pin (14, 16) to busbars (60, 62) of the high-voltage component (50) takes place via the internal thread (68) formed in the busbars (60, 62) or via a threaded bushing (70) arranged on the busbars (60, 62).

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