Adapter, manufacturing process, measurement process and associated assembly

Abstract

Adapter (100) for connecting a measuring device to an electrical circuit located in a vehicle, the adapter comprising: A body (160), First connectors (110) carried by the body, the first connectors (110) being of a first type, and being configured to be connected to electrical contact terminals (310) of the electrical circuit, the electrical contact terminals (310) being located, with power electronic devices of the electrical circuit, inside a compartment (300) of the vehicle, Second connectors (150) carried by the body (160), of a second type different from the first type, electrically connected to the first connectors (110),the body (160) being shaped to be fixed to the compartment (300) and to close an opening in the compartment (300) such that the first connectors (110) are located inside the compartment (300) and the second connectors (150) are located outside the compartment (300). Figure for the abbreviation: Figure 2,

Description

Title of the invention: Adapter, manufacturing method, measuring method and associated assembly technical field

[0001] The present invention relates to battery-powered electric propulsion motor vehicles Previous technique

[0002] In electric motor vehicles, power electronic devices are confined within a sealed compartment, such as the DC / DC converter, the inverter, and sometimes the on-board charger. The electrical contacts and connections are thus protected within this compartment to meet electrical protection standards.

[0003] However, there is a need to connect electrically safely to these electrical contact terminals when a motor vehicle is being tested, for example to estimate the capacity of the motor vehicle's power supply battery, for example in order to certify the motor vehicle or to demonstrate the production conformity or the in-service conformity of the motor vehicle. Description of the invention

[0004] The invention aims to overcome this drawback and relates, according to one of its aspects, to an adapter for connecting a measuring device to a high-voltage electrical circuit located in a motor vehicle, the adapter comprising: - A body, - The first electrical connectors carried by the body, the first electrical connectors being of a first type, and being configured to be connected to electrical contact terminals of the high-voltage electrical circuit, the electrical contact terminals being located, with power electronic devices of the high-voltage electrical circuit, inside a compartment of the motor vehicle, - Second electrical connectors carried by the body, of a second type different from the first type, electrically connected to the first electrical connectors,

[0005] The body being shaped to be fixed to the compartment and to then close an opening (in other words: completely block the opening) of the compartment so that the first electrical connectors are inside the compartment and the second electrical connectors open onto the outside of the compartment.

[0006] For the small proportion of approved or tested motor vehicles, the adapter can be used safely because the body then closes the compartment instead of the hood, and measurements can be taken via the second connectors which can be chosen to offer better electrical safety than the electrical contact terminals.

[0007] For example, by high voltage electrical circuit, we mean a circuit capable of operating at (in other words, capable of being powered by) an electrical voltage between 120 volts and 1500 volts.

[0008] For example, the body is made of plastic.

[0009] For example, the electrical contact terminals are connected in use to the electrical contact terminals of the power supply battery of an electric motor of the motor vehicle.

[0010] For example, power electronics devices include:

[0011] An inverter (an inverter is capable of transforming the direct current from the power supply battery into an alternating current to drive an electric motor),

[0012] A charger (a charger is capable of receiving a charging current from a charging station and transforming this current to the voltage used by the power supply battery),

[0013] A DC-DC converter (also called a DC / DC converter. It is capable of transforming a DC signal at a first voltage level into a DC signal at a second voltage value).

[0014] For example, the power supply battery produces a current of a voltage of 250 volts, 400 volts or 800 volts when in use.

[0015] The compartment is, for example, watertight when the cover (or the body or the plate as mentioned below) is attached to the compartment. The compartment may include a sealing gasket between the cover (or the body or the plate as mentioned below) and the rest of the compartment.

[0016] For example, the first type of connector and the second type of connector differ in their dimensions and / or shape and / or composition materials.

[0017] According to one embodiment, the first electrical connectors are connectors with annular clamping eyelets. Alternatively, of course, it could be a connector of another type, for example comprising flat and / or round terminals.

[0018] For example, the first electrical connectors and the second electrical connectors consist of a positive terminal and a negative terminal.

[0019] According to one embodiment, the first electrical connectors are connected to the second electrical connectors (in other words; are attached to the body) by electrical wires of a length between 10 centimeters and 30 centimeters. Thus, the electrical wires are long enough to allow the first electrical connectors to be connected to the electrical contact terminals while the body is away from the compartment. Alternatively, the first electrical connectors are mounted on the body so that they connect to the electrical contact terminals at the same time as the body is fixed to the compartment.

[0020] According to one embodiment, the body comprises a housing receiving the second electrical connectors and a plate fixed to the housing and from which the first electrical connectors emerge, the plate protruding laterally relative to the housing, and being shaped to be fixed to the compartment and to close (in other words: to seal) the opening of the compartment.

[0021] Thus, the plate can replace the cover when the latter is attached to the compartment. Of course, other body structures are possible.

[0022] According to one embodiment, the plate has a non-planar surface topology on the side opposite the housing.

[0023] For example, the surface topology is designed to adapt to the shape of an external surface of the compartment, around the opening. The aim may then be to trick vehicle-side presence sensors, configured to detect the presence of the hood in its position on the compartment, so as to only allow the vehicle to start when the hood is in its position on the compartment.

[0024] For example, the plate is made of an electrically insulating material, for example plastic.

[0025] According to one embodiment, the second electrical connectors consist of female banana plugs (for example, included in the housing), for example adapted and secured for high voltages. Alternatively, the second electrical connectors are of a different type.

[0026] The invention also relates, according to another aspect, to a method for manufacturing the adapter comprising the following steps:

[0027] Manufacture of the casing, and

[0028] Manufacturing the plate, for example by additive manufacturing (in other words: by 3D printing),

[0029] Then, assembly of the plate with the housing.

[0030] This allows the adapter to be adapted to different types of vehicles, in other words, to different types of hoods, by simply changing the plate.

[0031] Additive manufacturing makes it easy to create a complex surface topology, adapted to fit the shape of the compartment around the opening.

[0032] The invention also relates to a method for measuring an electrical quantity of a high-voltage electrical circuit in a motor vehicle, using the adapter, the high-voltage electrical circuit comprising electrical contact terminals and power electronic devices located together inside a compartment closed by a hood, the hood being fixed to the compartment by first fastening means, the measurement method comprising the following steps:

[0033] Remove the compartment cover to free access to an opening in the compartment, then

[0034] Connect the first electrical connectors of the adapter to the electrical contact terminals in the compartment,

[0035] Secure the adapter body to the compartment, by means of second fastening means, to close the opening, so that the first electrical connectors are inside the compartment and the second electrical connectors open onto the outside of the compartment,

[0036] Connect an electrical quantity measuring device to the second electrical connectors of the adapter, and measure said electrical quantity (using the electrical device).

[0037] It is understood that when the cover is attached to the compartment by means of the first fastening means, or when the body is attached to the compartment by means of the second fastening means, the electrical contact terminals are not accessible from outside the compartment. Conversely, when the cover or the body is removed from the compartment, the electrical contact terminals are accessible from outside the compartment.

[0038] According to one embodiment, the first electrical connectors are connected to the electrical contact terminals while the body is at a distance from the compartment.

[0039] Alternatively, the first electrical connectors connect to the electrical contact terminals at the same time as the body is fixed to the compartment by the second fixing member.

[0040] In one embodiment, the physical quantity is an electrical voltage across the terminals of a power supply battery for an electric propulsion motor of the electric vehicle. The step in which the physical quantity is measured can then be implemented using a voltmeter connected to the second set of electrical connectors. The first set of electrical connectors and the electrical contact terminals are then, for example, connected to the terminals of the power supply battery.

[0041] For example, the measurement method includes a step of determining the capacity (in kWh) of the power supply battery.

[0042] Alternatively, the physical quantity is a voltage across the terminals of another electrical component of the motor vehicle.

[0043] The invention also relates to an assembly comprising:

[0044] A compartment enclosing power electronics devices of a high-voltage electrical circuit for a motor vehicle, as well as electrical contact terminals of said high-voltage electrical circuit;

[0045] A cover, capable of being attached to the compartment by first fastening means, the cover being capable of being removed from the compartment so as to free access to an opening in the compartment; and

[0046] The adapter, the body of the adapter being able to be fixed to the compartment by means of second fixing means, and the body being shaped to close (in other words: to seal) the opening so that the first electrical connectors are inside the compartment and the second electrical connectors open onto the outside of the compartment, the first electrical connectors being configured to be connected to the electrical contact terminals.

[0047] According to one embodiment, the hood and the body (for example, the plate below) are configured to be detected (as being attached to the compartment) by a presence detector of the motor vehicle (for example, located in the compartment) for example causing a cut-off of the electrical supply received by the power electronic devices from the supply battery (and / or the high voltage electrical circuit), when the presence detector detects that the hood or the body is not present.

[0048] According to one embodiment, the second and first fastening means consist of the same fastening means. In other words, for example, the same screws and / or nuts can be used to fasten the plate to the compartment and to fasten the cover to the compartment.

[0049] Alternatively, these are separate fastening means.

[0050] For example, the first means of fastening and / or the second means of fastening include a screw or a nut or, alternatively, clips.

[0051] For example, the electrical contact terminals are in a cavity in the compartment accessible when the cover has been removed. Alternatively, the electrical contact terminals are at the same level as the cover, particularly when the cover is electrically insulating.

[0052] The walls of the compartment and / of the hood can be made of plastic or metal, for example.

[0053] According to one embodiment, the assembly further comprises a presence sensor configured to detect the presence of the hood in position on the compartment opening, the body being shaped (for example: the geometric shape of the body being shaped) so that said presence sensor determines the presence of the hood in position on the compartment opening, when the body is fixed to the compartment so as to close (in other words: to block) said opening.

[0054] The sensor is, for example, a contactor that closes a safety electrical circuit when activated. This sensor is located under the hood, and its activation is ensured by the hood's geometric shape. This safety feature cuts off the power supply from the battery, preventing the vehicle from being used.

[0055] The invention finally relates to a motor vehicle comprising the assembly.

[0056] According to one embodiment, the electrical contact terminals are intended to verify that there is no residual voltage from the power supply battery when the motor vehicle is locked out, i.e., when the power supply battery is disconnected from the motor vehicle's electrical circuits (for example, by actuation of an electrical switch or contactor) (and the measurement method according to the invention may include such a verification step prior to the step where the first electrical connectors are connected to the electrical contact terminals). Thus, the invention can make it possible to reuse contact terminals intended for a common operation, namely locking out, to implement the measurement method.

[0057] Although they are not systematically repeated or copied for each object, the advantages and characteristics of the manufacturing process, the measuring process, the adapter and the assembly are identical (mutatis mutandis). Brief description of the drawings

[0058] The invention will be better understood upon reading the detailed description that follows, the non-limiting examples of its implementation, and upon examination of the accompanying drawings, in which:

[0059] [Fig. 1] schematically represents a system comprising a compartment with a hood, a power supply battery and an electric motor in a motor vehicle,

[0060] [Fig.2] schematically represents the system of [Fig.1], the hood being by an adapter according to the invention, and the adapter being in a first position relative to the compartment,

[0061] [Fig.3] represents the system of [Fig.2], in which the adapter is in a second position relative to the compartment;

[0062] [Fig.4] schematically represents the steps of a measurement process, according to an embodiment of the invention, implemented using the adapter of figures 2 and 3.

[0063] To facilitate the reading and legibility of these figures, certain elements in these figures are visible through (fictitious) transparency of other elements in these figures. By example [Fig.l], 2 and 3, the 150 plugs are seen through (fictitious) transparency of the 120 case. Detailed description

[0064] Fig. 1 represents, in a motor vehicle, a compartment 300, an electric motor 400 and a power supply battery 200 for the electric motor 400.

[0065] The compartment 300 includes electrical contact terminals 310 which are electrical contact terminals of the power supply battery 200 which produces, for example, a voltage of 400 volts.

[0066] The compartment 300 includes a cover 330 fixed by means of first fixing means, here nuts of the compartment 300 (not shown) and screws.

[0067] The compartment 300 may include a seal 320 between the hood 330 and the rest of the compartment.

[0068] The walls of compartment 300 and / or cover 330 may, for example, be made of metal.

[0069] When cover 330 is attached to compartment 300 by means of the aforementioned first fastening means (and closes compartment 300), the electrical contact terminals 310 are not accessible from outside the compartment.

[0070] For example, the electrical contact terminals 310 are in a cavity (not shown) in the compartment 300, accessible when the cover 330 is removed.

[0071] For example, compartment 300 includes an inverter 340, a charger 350, and a DC / DC converter 360 which, together with the electrical contact terminals 310, form part of an electrical circuit 500.

[0072] The compartment 300 includes a presence detector 370. When the presence detector 370 detects that the cover 330 is not present, the power supply, from the power supply battery 200, and in particular to the inverter 340, the charger 350, the DC / DC converter 360 is automatically cut off.

[0073] The presence detector 370 is for example a contactor closing the electrical circuit 500 when the cover 330 (or the plate 130) is detected, or opening the electrical circuit 500 otherwise.

[0074] With reference to [Fig.4], in step S00, the cover 330 of compartment 300 is removed. An adapter 100 is then brought close to the compartment.

[0075] The adapter 100 comprises a body 160. The body 160 comprises a housing 120, for example made of plastic, and a plate 130, for example made of plastic, attached to the housing 120 (for example, by adhesive). The housing 120 comprises second electrical connectors, here plugs 150, which are, for example, female banana plugs, for example adapted and secured for high voltages. The adapter 100 also comprises the first electrical connectors 110, the plugs 150 being connected in use to the first electrical connectors 110 via the electrical wires 140.

[0076] At step S10, the first electrical connectors 110 are connected to the electrical contact terminals 310. For example, the first electrical connectors 110 are connectors with annular clamping eyelets.

[0077] As shown [Fig.2], the first electrical connectors 110 are then connected to the plugs 150 by electrical wires 140 from the adapter 100 which have a length of 20 centimeters to allow a connection of the first electrical connectors 110 to the electrical contact terminals 310, while the body 160 is at a distance from the compartment 300.

[0078] At step S20, the plate 130 is fixed to the compartment by means of second fixing means, the plate 130 then closing the compartment 300, i.e. the opening, in place of the cover 330. This configuration is shown [Fig.3].

[0079] Preferably, the same fastening means, such as screws and nuts, constitute both the first and second fastening means. This implies that the plate 300 has through holes in the same locations as the hood.

[0080] The first electrical connectors 110 are then located inside the compartment 300 and the plugs 150 open onto the outside of the compartment 300.

[0081] In step S30, a voltage across the terminals of the plugs 150 is measured by a voltmeter (not shown) comprising plugs (for example male banana plugs) connected to the plugs 150 during tests intended to measure a voltage representative of the state of charge of the supply battery 200. These tests can last several days and, thanks to the adapter, the voltage measurements are safe without requiring the intervention of qualified personnel, and without any other assembly or disassembly.

[0082] During step S30, the presence of plate 130 is of course detected by the presence detector 370, which allows a power supply from the power supply battery 200, and in particular to the inverter 340, the charger 350, the DC / DC converter 360.

[0083] When the vehicle only allows power from the auxiliary battery 200 if the presence of the hood on the compartment 300 is detected by the presence detector 370, the invention avoids the need to drill through the hood to run electrical wires. Here, it is proposed that the plate 130 have the same shape as the hood, at the edges surrounding the opening, which allows the presence detector 370 to be deceived.

[0084] When the plate 130 is fixed to the compartment 300 by means of second fastening means (and closes the compartment 300), the electrical contact terminals 310 and the first electrical connectors 110 are not accessible from outside the compartment.

[0085] On the contrary, when the cover 330 or the body (or the plate 130) is removed from the compartment then the electrical contact terminals 310 (and / or the connectors 110) are accessible from outside the compartment.

[0086] The first electrical connectors 110 and plugs 150 consist, for example, of a positive terminal and a negative terminal. Alternatively, the invention can be implemented in the context of a three-phase current.

Claims

Demands

1. Adapter (100) for connecting a measuring device to a high-voltage electrical circuit located in a motor vehicle, the adapter comprising: - A body (160), - First electrical connectors (110) carried by the body, the first electrical connectors (110) being of a first type, and being configured to be connected to electrical contact terminals (310) of the high-voltage electrical circuit, the electrical contact terminals (310) being located, with power electronic devices of the high-voltage electrical circuit, inside a compartment (300) of the motor vehicle, - Second electrical connectors (150) carried by the body (160), of a second type different from the first type, electrically connected to the first electrical connectors (110),the body (160) being shaped to be fixed to the compartment (300) and to then close an opening in the compartment (300) so that the first electrical connectors (110) are located inside the compartment (300) and the second electrical connectors (150) open onto the outside of the compartment (300).

2. Adapter according to the preceding claim in which the first electrical connectors (110) are connected to the second electrical connectors (150) by electrical wires (140) of a length between 10 centimeters and 30 centimeters.

3. Adapter (100) according to any one of the preceding claims in which the second electrical connectors (150) are made up of female banana plugs.

4. Adapter according to any one of the preceding claims in which the body (160) comprises a housing (120) receiving the second electrical connectors (150) and a plate (130) fixed to the housing and from which the first electrical connectors (110) emerge, the plate (130) protruding laterally relative to the housing, and being shaped to be fixed to the compartment (300) and to then close the opening of the compartment (300).

5. Adapter according to claim 4, wherein the plate (130) has a non-planar surface topology on the side opposite the housing (120).

6. Method of manufacturing an adapter (100), according to claim 4 or 5 comprising the following steps: - Manufacturing the housing (120), and - Manufacturing the plate (130), by additive manufacturing, - Assembling the plate (130) with the housing (120).

7. A method for measuring an electrical quantity of a high-voltage electrical circuit in a motor vehicle, using an adapter (100) according to any one of claims 1 to 6, the high-voltage electrical circuit comprising electrical contact terminals (310) and power electronic devices located together inside a compartment (300) closed by a cover (330), the cover (330) being attached to the compartment (300) by first fastening means, the measurement method comprising the following steps: - Removing (S00) the cover (330) from the compartment (300) to provide access to an opening (380) in the compartment (300), then - Connecting (S10) the first electrical connectors (110) of the adapter (100) to the electrical contact terminals (310) in the compartment (300), - Securing (S20) the body (160) of the adapter (100) to compartment (300), via second fastening means,to close the opening (380) so that the first electrical connectors (110) are inside the compartment (300) and the second electrical connectors (150) open onto the outside of the compartment (300), - Connect (S30) a measuring device for an electrical quantity to the second electrical connectors (150) of the adapter (100), and measure (S30) said electrical quantity.

8. A measuring method according to the preceding claim, the adapter (100) being the adapter (100) according to claim 2 or according to any one of claims 3 to 6, taking into account the claim 2, wherein the first electrical connectors (110) are connected to the electrical contact terminals (310) while the body is at a distance from the compartment (300).

9. A measurement method according to claim 7 or 8 wherein the electrical quantity is an electrical voltage across the terminals of a power supply battery (200) of an electric propulsion motor (400) of the motor vehicle.

10. Assembly comprising: - A compartment (300) enclosing power electronics devices of a high-voltage electrical circuit for a motor vehicle, as well as electrical contact terminals (310) of said high-voltage electrical circuit; - A cover (330), capable of being fixed to the compartment (300) by first fastening means, the cover (330) being capable of being removed from the compartment (300) so as to free access to an opening (380) in the compartment (300);and - An adapter (100) according to any one of claims 1 to 6, the body (160) of the adapter (100) being able to be fixed to the compartment (300) by means of second fixing means, and the body (160) being shaped to close the opening (380) so that the first electrical connectors (110) are inside the compartment (300) and the second electrical connectors (150) open onto the outside of the compartment (300), the first electrical connectors (110) being configured to be connected to the electrical contact terminals (310).

11. Assembly according to the preceding claim in which the second fastening means and the first fastening means are constituted by the same fastening means.

12. An assembly according to claim 10 or 11, further comprising a presence sensor configured to detect the presence of the cover (330) in position on the opening (380) of the compartment (300), the body (160) being shaped so that said presence sensor determines the presence of the cover (330) in position on the opening of the

13. compartment (300), when the body (160) is fixed to the compartment (300) so as to close said opening (380). Motor vehicle comprising the assembly according to any one of claims 10 to 12.

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