Charging connector for an electric or hybrid vehicle

Abstract

The invention relates to a charging connector (1) for an electric or hybrid vehicle, having a housing (2), charging contacts (3) arranged in the housing for conducting electric current, and a communication module (4) for transmitting and / or receiving a serial signal. In this way, communication between a charging connector (1) for an electric or hybrid vehicle and an external device can be simplified and made more efficient.

Description

[0001] Charging connector for an electric or hybrid vehicle

[0002] The invention relates to a charging connector for an electric or hybrid vehicle, comprising a housing and charging contacts arranged in the housing for conducting electrical current.

[0003] Electric and hybrid vehicles have a rechargeable energy storage device, usually a high-voltage battery, which supplies energy to an electric drive motor during operation. The storage capacity of these high-voltage batteries is limited, so they must be recharged regularly at a charging station. The battery is charged using a charging cable provided between the charging station and the vehicle. The charging cable, for example, is equipped with a charging plug on one end that can be plugged into a charging socket provided on the charging station, and on the other end with a charging coupling that can be connected to a charging plug installed in the electric or hybrid vehicle, in accordance with the European standard IEC 62196. For the purposes of this article, charging sockets, charging plugs, charging couplings and charging plugs are all referred to as “charging connectors”.Charging sockets and charging couplings have contact sleeves as charging contacts, and charging plugs as well as charging plugs that can be installed in electric and hybrid vehicles have contact pins as charging contacts that fit into the.

[0004] Contact sleeves are insertable. The plug contacts between a charging plug and a charging coupling are subject to increased surface wear due to frequent use and repeated plugging and unplugging. This wear leads to an increase in contact resistance, which can cause significant heat generation during the charging process.

[0005] Charging connectors for electric and hybrid vehicles are subject to legal and user-specific requirements regarding the temperature monitoring of AC and DC charging contacts. For DC charging, temperature measurement is generally required at both DC charging contacts. For this purpose, a component suitable for temperature measurement, usually an NTC resistor, is placed as close as possible to the heat source, i.e. the charging contact, in order to enable real-time temperature monitoring for charging optimization and safety monitoring. An NTC resistor is a resistor used in electronic components. It is also known as a thermistor or hot wire. The abbreviation "NTC" stands for "negative temperature coefficient" and describes the property of hot wire resistors to conduct electricity better as the temperature increases because they have a negative temperature coefficient.

[0006] PTC resistors are also known. A PTC resistor, also called a PTC thermistor ("positive temperature coefficient"), is also a temperature-dependent resistor, although it conducts electrical current better at low temperatures than at high temperatures. PTC resistors exist that have an almost linear characteristic curve (resistance as a function of temperature). However, PTC resistors are also known that behave non-linearly and whose resistance increases sharply near the nominal response temperature. Such PTC elements can therefore be used to implement a type of "fuse" by returning a rapidly changing value to a reading system when the critical temperature is exceeded.

[0007] Temperature monitoring may also be required for AC charging contacts. Depending on the standard and manufacturer's specifications, either an actual temperature measurement or merely detection of exceeding a temperature threshold is necessary. This may be required either for all AC charging contacts (e.g., LI, L2, L3, and N for connectors conforming to the European standard IEC 62196 Type 2), separately for each AC charging contact, or collectively, i.e., for all AC charging contacts together.

[0008] DE 10 2015 106 251 A1 describes a temperature monitoring device with a carrier element extending flatly along a plane and having at least one opening. The carrier element can be designed as a printed circuit board. The contact elements are components of a contact assembly which can be attached to the plug insert as a modular unit. The contact assembly has a temperature monitoring device with a carrier element. The temperature monitoring device serves to detect any inadmissible heating on at least those contact elements which are used to transmit large currents during operation of the plug connector part. For the necessary contacting, the carrier element has a metallic coating on each of the openings to provide a contact surface in the form of a through-hole connection.

[0009] An electrical assembly with a temperature monitoring device is known from WO 2021 / 004765 A1. For this purpose, a connector part with both AC charging pins and DC charging pins is provided. To monitor potential heating, particularly at the DC charging pins, the connector part has an electrical assembly. This assembly consists of contact elements arranged on a carrier element and electrically connected to associated load lines. For this purpose, each contact element is received in an associated receiving opening in the carrier element.

[0010] Based on this, the object of the invention is to design the communication between a charging connector for an electric or hybrid vehicle and an external device in a simple and efficient manner.

[0011] This object is achieved by the subject matter of the independent claims. Preferred developments of the invention are described in the subclaims. According to the invention, a charging connector for an electric or hybrid vehicle is thus provided, comprising a housing, charging contacts arranged in the housing for conducting electrical current, and a communication module for transmitting and / or receiving a serial signal.

[0012] The basic idea of ​​the invention is that various sensor data can be transmitted over just one or a few signal lines if a communication module is provided for sending and / or receiving a serial signal. The information flow can be significantly increased in this way, which benefits additional diagnostic requirements and performance demands.

[0013] Basically, it should be noted with regard to the charging connector according to the invention that it is intended for plugging into a corresponding charging connector. According to a preferred development of the invention, the communication module is designed such that, when the charging connector is plugged in, it allows communication to and / or from the corresponding charging connector. In this way, communication is possible via a charging cable between a charging station and an electric or hybrid vehicle connected to the charging station via the charging cable.

[0014] When reference is made here to a corresponding charging plug connector, this means, on the one hand, a charging plug connector which has the same plug face as the charging plug connector according to the invention, whereby one plug face has contact pins while the other plug face has contact sleeves, and vice versa. The set comprising the charging plug connector according to the invention and the corresponding charging plug connector can therefore be plugged together. On the other hand, the term corresponding charging plug connector is also used here when the plug faces in the aforementioned sense only partially correspond, i.e. the corresponding charging plug connector, for example.does not have all the contacts that are present in the charging plug connector according to the invention, but the existing contacts of the corresponding charging plug connector correspond to the charging plug connector according to the invention in terms of the plug face, so that the charging plug connector according to the invention and the corresponding charging plug connector can be plugged together in this case too. Such a case occurs, for example, with a charging coupling for direct current charging according to the European standard IEC 62196 Type 2 that is connected to a charging cable. Such a charging coupling can be plugged into a charging plug that is installed in the body of an electric or hybrid vehicle and is suitable for alternating current charging as well as direct current charging, wherein in the alternating current plug face of the direct current charging coupling only the communication contacts and the protective contact are present, but no contacts for the outer conductor and a center conductor for alternating current charging.

[0015] In principle, the communication module can be arranged inside the housing. However, this is not mandatory. In this respect, the communication module can be arranged inside or outside the housing. Arranging the communication module outside the housing can be particularly advantageous if the charging connector is a built-in charging connector that is attached to the body of an electric or hybrid vehicle. In this case, there is usually enough space within the body to install the communication module without it disturbing or obstructing other devices.

[0016] There are various options for designing the communication module. According to a preferred development of the invention, the communication module comprises a multiplexer for multiplexing signals detected in or on the charging plug connector. Specifically, in this context it is preferred that a temperature sensor for detecting the temperature of the respective charging contact is arranged on a plurality of the charging contacts and that the temperature sensors are connected to the multiplexer so that temperature signals originating from the temperature sensors can be transmitted to the multiplexer and converted by the multiplexer into a serial data stream. Temperature monitoring of the DC charging contacts of a charging plug connector for an electric or hybrid vehicle is already required by the standard (European standard IEC 62196).Preferably, however, the temperatures of the DC charging contacts should also be monitored, and preferably all AC charging contacts. In the present case, contacts that are intended exclusively for charging with DC current are referred to as DC charging contacts. With such DC charging contacts, heating occurs particularly when charging with high currents. In contrast to DC contacts, there are AC charging contacts. This refers to the outer conductors and the neutral conductor (center conductor), which are also intended for charging with AC current. An outer conductor (also colloquially referred to as a phase) is a conductor that is live during normal operation and can contribute to the transmission or distribution of electrical energy, but is not a neutral conductor.A neutral conductor is a conductor that is electrically connected to the neutral point and is capable of contributing to the distribution of electrical energy. In the European standard IEC 62196, the contacts, which are referred to here as AC charging contacts, are designated LI, L2 and L3 (line conductors) and N (neutral conductor), and the DC charging contacts are designated DC+ and DC-. This understanding should not be contradicted by the fact that the European standard IEC 62196 also recognizes an operating mode according to which direct current charging takes place via the contacts LI, L2, L3 and N.

[0017] When using a temperature-dependent resistor, a separate signal line would have to be run to an evaluation unit for each AC contact to monitor the temperature of the AC charging contacts. Alternatively, a series circuit can be used, e.g. consisting of PTC elements. However, such a series circuit does not allow any conclusions to be drawn about the individual temperature of individual AC charging contacts. The use of a multiplexer now makes it possible to bundle signals and send them serially via a single signal line. The multiplexer can either be controlled via control lines, so that a specific channel is selected, or a periodic change of channels is triggered via a clock generator and synchronized with the evaluation unit.In this respect, according to a preferred embodiment of the invention, at least one control line is connected to the multiplexer in order to control the temporal sequence of the temperature signals originating from the temperature sensors in the serial data stream. Alternatively, it is possible for the temperature signals originating from the temperature sensors to follow one another periodically in the serial data stream.

[0018] By using the multiplexer, many signal lines can be bundled into a single one. A suitable multiplexer must be selected depending on the number of inputs (four inputs to one output - 4:1, eight inputs to one output - 8:1, . . . ). The number of control lines also increases with the number of inputs. For example, a 4:1 multiplexer requires two control lines, while an 8:1 multiplexer requires three. One advantage of external control of the multiplexer is that only those lines can be queried which are of interest to the evaluation unit. This means that if only AC charging is taking place, the DC temperature sensors can be ignored and more time can be spent on the AC temperature sensors. As already mentioned, an alternative to this is that all input signals can be periodically queried and the multiplexer clock can then be synchronized with the evaluation unit.This reduces the number of control lines to one for the clock, but also leads to a reduction in flexibility, since each input line is now mapped to the output the same number of times and for the same length of time.

[0019] According to a preferred development of the invention, the communication module can additionally or alternatively be set up to receive digital signals. In this context, it is very particularly preferred that the communication module is set up for bidirectional communication of serial signals. In this way, the charging connector can not only send signals but also receive them, e.g. in order to control a device of the charging connector. In this respect, according to a preferred development of the invention, the charging connector is additionally provided with an actuator and a control device for controlling the actuator, the communication module being connected to the control device for transmitting a control signal received by the communication module.

[0020] Most preferably, the charging connector is a built-in charging connector for attachment to the body of an electric or hybrid vehicle. Furthermore, the invention also relates to the use of a previously described charging connector on the body of an electric or hybrid vehicle.

[0021] Finally, the invention also relates to a method for communication between a charging connector for an electric or hybrid vehicle and a device different from the charging connector, wherein the communication takes place by means of a serial signal. According to a preferred embodiment of the invention, the charging connector outputs a signal converted by means of a multiplexer. Alternatively or additionally, it is preferably provided that the charging connector sends and / or receives a digital signal. Further embodiments, functions and advantages of this method arise analogously to the charging connector described above.

[0022] The invention is explained in more detail below with reference to the drawings using preferred embodiments.

[0023] The drawings show

[0024] Fig. 1 shows a charging connector in a perspective view according to a preferred embodiment of the invention,

[0025] Fig. 2 shows a charging connector corresponding to the charging connector from Fig. 1 in a perspective view, Fig. 3 shows schematically a charging connector according to a preferred embodiment of the invention with a multiplexer and

[0026] Fig. 4 schematically shows a charging connector according to a preferred embodiment of the invention with a digital part for receiving digital control data.

[0027] Fig. 1 shows a perspective view of a charging connector 1 according to a preferred embodiment of the invention. The charging connector 1 has a housing 2 and charging contacts 3 arranged in the housing 2. These are, on the one hand, alternating current charging contacts 8 for alternating current charging and, on the other hand, direct current charging contacts 9 for direct current charging. The charging connector 1 shown in Fig. 1 is a charging plug for installation in the body of an electric or hybrid vehicle.

[0028] The charging connector 1 can be coupled to a corresponding charging connector 12, which is shown in Fig. 2. This is a charging coupling that can be attached to a charging cable and plugged together with the charging plug. The charging coupling shown here as an example is for direct current charging and therefore has corresponding direct current charging contacts 13, a protective contact 14 and signal contacts 15. Both the charging plug shown here and the coupling shown here correspond to the European standard IEC 62196 in terms of their plug face.

[0029] What is important now is that the charging plug 1 according to a preferred embodiment of the invention is designed, for example, as shown schematically in Fig. 3:

[0030] The charging connector is equipped with a communication module 4 for transmitting a serial signal. For this purpose, the communication module 4 has a multiplexer 5 for multiplexing signals detected in the charging connector 1. Specifically, both the direct current charging contacts 9 and the alternating current charging contacts 8 are each provided with a temperature sensor 6. In this case, the temperature sensors 6 are NTC elements.

[0031] With these temperature sensors 6, the respective temperature can be determined individually at each DC charging contact 9 or at each AC charging contact 8. The temperature sensors 6 are now connected to the multiplexer 5 in such a way that the temperature signals originating from the temperature sensors 6 are transmitted to the multiplexer 5, so that they can then be converted by the multiplexer into a serial data stream. This serial data stream is then fed via the signal lines 7 to an evaluation unit (not shown in more detail), which is separate from the charging connector 1. In principle, control lines could be connected to the multiplexer 5 in order to control the temporal sequence of the temperature signals originating from the temperature sensors 6 in the serial data stream.With the help of such control lines, it could be determined which temperature sensor 6 the data is of interest and should therefore be fed to the evaluation unit. In this case, however, the temperature signals originating from the temperature sensors 6 follow one another periodically in the serial data stream. For example, a sequence of temperature signals could be provided in which the temperature signals for the two DC charging contacts 9 are followed by the temperature signals for the four AC charging contacts 8, and so on. In other words, using the nomenclature from the European standard IEC 62196, the sequence would be "DC+, DC-, LI, L2, L3, N, DC+, . . . ".

[0032] Fig. 4 now shows schematically a charging connector 1 according to another preferred embodiment of the invention with a digital part 16 arranged in the communication module 4 for receiving digital control data. In this case, control data is received from outside the charging connector 1 via the signal lines 7 in order to initiate control for a component of the charging connector 1. In this case, the charging connector 1 has a locking flap 17 with which the opening, within which the AC charging contacts 8 and the DC charging contacts 9 are arranged, can be closed off and locked from the outside. An actuator 10, here in the form of an electric motor, is provided for opening and closing this locking flap 17. The actuator 10 is connected to a control device 11, by means of which the actuator 10 can be controlled in such a way that the locking flap 17 opens or closes.closes. Corresponding signals which specify an opening or closing of the locking flap 17 are fed to the control device 11 from outside the charging connector, namely via the signal lines 7 and the communication module 4 having the digital part 16. It should also be noted that the communication module 4 in this case is set up for bidirectional communication of serial signals, so that it can not only receive signals which specify whether the locking flap 17 should be closed or opened. Rather, it is also possible here for the control device to transmit data to the digital part 16 of the communication module 4 which indicate the current position of the locking flap 17, i.e. open or closed, so that this information can be output in the form of digital data via the signal lines 7.

[0033] Reference symbol list

[0034] 1 charging connector

[0035] 2 housings

[0036] 3 charging contacts

[0037] 4 Communication module

[0038] 5 multiplexers

[0039] 6 temperature sensors

[0040] 7 signal lines

[0041] 8 AC charging contacts

[0042] 9 DC charging contacts

[0043] 10 Actuator

[0044] 11 Control device

[0045] 12 corresponding charging connectors

[0046] 13 corresponding DC charging contacts

[0047] 14 Protective contact

[0048] 15 signal contacts

[0049] 16 Digital part

[0050] 17 Locking flap

Claims

Patent claims 1. Charging connector (1) for an electric or hybrid vehicle, with a housing (2), charging contacts (3) arranged in the housing (2) for conducting electrical current and a communication module (4) for transmitting and / or receiving a serial signal.

2. Charging connector (1) according to claim 1, wherein the communication module (4) comprises a multiplexer (5) for multiplexing signals detected in or on the charging connector (1).

3. Charging connector (1) according to claim 2, wherein a temperature sensor (6) for detecting the temperature of the respective charging contact (3) is arranged on a plurality of the charging contacts (3), and the temperature sensors (6) are connected to the multiplexer (5), so that temperature signals originating from the temperature sensors (6) can be transmitted to the multiplexer (5) and converted by the multiplexer into a serial data stream.

4. Charging connector (1) according to claim 3, wherein the charging contacts (3) each equipped with a temperature sensor (6) comprise AC charging contacts (8).

5. Charging connector (1) according to one of the preceding claims, wherein the communication module (4) has a digital part (16) for receiving digital signals.

6. Charging connector (1) according to one of the preceding claims, wherein the communication module (4) is configured for bidirectional communication of serial signals.

7. Charging connector (1) according to one of the preceding claims, with an actuator (10) and a control device (11) for controlling the actuator (10), wherein the communication module (4) is connected to the control device (11) for transmitting a control signal received by the communication module (4).

8. Charging connector (1) according to one of the preceding claims, wherein the charging connector is a charging plug for attachment to the body of an electric or hybrid vehicle.

9. Use of a charging connector (1) according to one of the preceding claims on the body of an electric or hybrid vehicle.

10. Method for communication between a charging connector (1) for an electric or hybrid vehicle and a device different from the charging connector (1), wherein the communication takes place by means of a serial signal.

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