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 whereby the required number of contactors can be realized at low cost and in a space-saving manner. According to the invention, this object is achieved in that the modular contactor box comprises a modular housing with a number of plug-in points for receiving respective contactor modules, at least two contactor modules, each having at least two contactor module connection contacts and each being accommodated in one of the plug-in points of the modular housing, and at least two contactor box connection contacts. At least two of the contactor modules are interconnected with each other such that the maximum number of contactor box connection contacts is at least one less than the number of contactor module connection contacts.

Description

[Technical field]

[0001] The present invention relates to a modular contactor box, especially for electric vehicles. [Background technology]

[0002] Modern climate and environmental protection goals cannot be achieved without road traffic also making a significant contribution. One of the key factors in this regard is the increasing electrification of all vehicle segments. This affects all areas, from private transport to public and commercial transport. For commercial transport, electric vehicles offer other major advantages in addition to the most important aspect of environmentally friendly driving: In direct comparison, the drives of electric vehicles require significantly less maintenance than conventionally powered vehicles and have a significantly longer service life. This results in significantly greater efficiency, especially over short and medium distances. Summary of the Invention [Problem to be solved by the invention]

[0003] Electric vehicles are powered by an electric motor that draws its energy from a large-capacity battery unit. The battery unit is charged in a charging station. To allow safe connection and disconnection of the battery unit both to the drive of the electric vehicle and to the charging station, each electric vehicle has a power supply system with several contactors. Depending on the application, between five and nine contactors can be provided. This results in an increase in the space required and therefore in costs.

[0004] It is therefore an object of the present invention to provide a concept which allows the required number of contactors to be realised with the required safety whilst reducing costs and the space required. [Means for solving the problem]

[0005] For this purpose, a modular contactor box according to the invention is provided, which comprises a module housing having a number of accommodation positions each accommodating one contactor module, at least two contactor modules each having at least two contactor module connection contacts and each being accommodated in one of the accommodation positions of the module housing, and at least two contactor box connection contacts, wherein at least two of the contactor modules are interconnected with each other such that the maximum number of the contactor box connection contacts is at least one less than the number of the contactor module connection contacts.

[0006] "Modular contactor box" means that the contactor box is constructed like a construction kit. The necessary components, in particular several contactor modules, are provided. These may be constructed identically but also different from each other depending on the required application. The necessary components / contactor modules are selected from a number of similar or different parts, in particular contactor modules, depending on the application.

[0007] The module housing has a number of receiving positions into which the required contactor modules can be easily inserted. The outer dimensions of the contactor modules can be configured to be identical, in which case the receiving positions are preferably also configured to be identical. However, it is also possible to provide contactor modules with different outer dimensions, in which case the receiving positions of the module housing are adjusted accordingly. This leads to a simpler construction and easier assembly of the contactor box. Since the outer dimensions of the contactor modules are as far as possible identical, identical components can be used, with the associated potential for cost savings. The contactor modules are preferably prefabricated or existing units which are easy to use. The integration of the contactor modules in the contactor box saves installation space and also leads to cost savings. Nevertheless, it is possible to adapt to customer-specific requirements.

[0008] The contactor module connection contacts are the connection contacts (contacts, terminals) of the contactor module. Together with the contactor module connection contacts, the contactor module is connected to the power line to be interrupted. Furthermore, each contactor module also comprises a number of switching contacts, preferably at least one movable contact and one fixed contact. The contactor box connection contacts are connection contacts (contacts, terminals) that are brought out of the contactor box module housing and allow the contactor box components to be connected to external lines. Since at least two of the contactor modules are connected to each other internally and the number of the contactor box connection contacts is at least one less than the number of the contactor module connection contacts, no additional electrical connections with connection conductors (e.g. screw connections) are required. This allows electrical losses to be reduced. If more than two contactor modules are connected to each other internally, the number of the contactor box connection contacts is correspondingly less. The contactor module connection contacts may be integrated into the contactor box connection contacts or may be configured as one piece with the contactor box connection contacts.

[0009] Preferred embodiments of the invention are the subject matter of the dependent claims.

[0010] In a preferred embodiment, the contactor modules, which are internally connected to one another, are connected to one another via a common connection member forming a contactor module connection contact. The connection member preferably also forms a contactor box connection contact. The connection member can be configured, for example, as a busbar. The connection member may thus be configured as a metal sheet or rail (wire-shaped) made of copper or aluminum. This allows for a simple and robust construction. Furthermore, the fixed contacts of the contactor modules may be formed on the busbar. Since the contactor modules are internally connected to one another, no additional contacts are required for the system. This leads to a reduction in the contact resistance.

[0011] In a further embodiment, more than two contactor modules can be interconnected with each other, preferably by a common connecting member configured as a multiple bridge, which further saves contacts in the system and provides the above-mentioned advantages.

[0012] It is advantageous if the contactor module can be plugged into the receiving location, which is configured as a plug-in point, into which the contactor module can simply be plugged during assembly. It is preferably possible to latch or fix the contactor module to the plug-in point.

[0013] In another preferred embodiment, each contactor module has at least one movable contact and at least one fixed contact. At least one fixed contact of at least one contactor module has a groove transverse to the closing direction of the contacts of the at least one contactor module, the groove side of said groove being at least partially oblique to the closing direction so as to form an angle not equal to 90° with respect to the closing direction. At least one movable contact of at least one contactor module is configured such that in the closed position of the contacts of the at least one contactor module, the contact points present between the fixed contact and the movable contact occur at the obliquely extending groove side. This avoids the need for additional contacts, which leads to a reduction in material, weight and structural volume as well as a reduction in transition resistance. In addition, the short circuit strength is improved.

[0014] Further savings in installation space can be achieved by configuring at least one arc-extinguishing area in the module housing, which extinguishes the electric arc that occurs when the contactor module is switched.

[0015] It is advantageous to allocate at least one extinguishing area to at least two contactor modules, which do not switch simultaneously. If an extinguishing area is used by more than one contactor module, the space required is further optimized.

[0016] In another preferred embodiment, at least one fuse may be arranged in the module housing. By integrating further components in the contactor box, the assembly in the vehicle is further simplified and the space required is optimized.

[0017] This can also be achieved by placing at least one pyroswitch inside the module housing, which also provides additional safety.

[0018] Further simplification of assembly can also be achieved if the contactor box further comprises a plug interface and / or if a sensor for measuring current is located within the module housing and / or if a tap point for measuring voltage is located within the module housing.

[0019] In yet another variant, at least one of the contactor modules may have at least one fixed contact and at least one movable contact, and a coil for driving the at least one movable contact. The coil may have a number of coil connections, all of which may be arranged on the module housing and contactable together. In this case, the coils of the contactor modules may be individually controlled. The coil connections may advantageously be controlled via a printed circuit board or a lead frame.

[0020] In yet another preferred embodiment, the contactor boxes may have a common control module located in a modular housing that can be installed in various locations to allow common control of the components located within the contactor boxes. [Brief description of the drawings]

[0021] [Figure 1] FIG. 2 is a schematic diagram showing electrical connections of a battery of an electric vehicle. [Diagram 2] FIG. 2 is a schematic diagram showing a traveling state of the electric vehicle shown in FIG. [Diagram 3] FIG. 2 is a schematic diagram showing charging of an electric vehicle at 800V in FIG. [Figure 4] FIG. 2 is a schematic diagram showing charging of an electric vehicle at 400V in FIG. [Diagram 5] FIG. 1 is a schematic diagram of a modular contactor box for an electric vehicle. [Figure 6] FIG. 6 is a diagram showing a module housing of the contactor box of FIG. 5. [Figure 7] FIG. 6 is a diagram showing a contactor module of the contactor box of FIG. 5. [Figure 8] FIG. 6 is a plan view of the contactor box of FIG. 5. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0022] Hereinafter, an embodiment of the present invention will be described in more detail with reference to the drawings.

[0023] In the following description, like parts are given like reference numerals. If a figure contains a reference numeral that is not explained in detail in the description associated with that figure, reference is made to the description of the preceding or following figure.

[0024] In an electric vehicle, contactors are required for charging the battery in different networks or charging stations and for connecting the battery to the electric motor. FIG. 1 is a schematic diagram showing the possible electrical connection of the battery 1 in an electric vehicle. The electric vehicle here has two batteries 1. The battery 1 can be connected to the drive of the electric vehicle, i.e. the motor, via vehicle connections 2, 3. A vehicle connection 4 is provided between the battery 1 and the vehicle connections 2, 3. Three main contactors 5 are arranged in the vehicle connection 4. Furthermore, the battery 1 can be connected to charging connections 7, 8 via a charging connection 6. The charging connection 6 is provided with two first charging contactors 9 for charging the battery 1 with 800 V and two second charging contactors 10 for charging the battery 1 with 400 V. In addition, fuses 11 and / or pyro switches 12 can be arranged in the charging connection 6 and / or in the vehicle connection 4.

[0025] Figure 2 shows the electrical connections of the battery 1 when the electric vehicle is in a running state. In this state, the battery 1 is connected to the vehicle connections 2, 3. The three main contactors 5 arranged in the vehicle connection line 4 are therefore closed and the battery 1 can supply current to the electric vehicle, i.e. to the drive of the electric vehicle. The first charging contactor 9 and the second charging contactor 10 are open.

[0026] Figure 3 shows the initial charging state of the battery 1. In this case, the battery 1 is electrically connected to the charging connections 7, 8 via the charging connection 6. For this purpose, both the first charging contactor 9 and the main contactor 5 arranged between the two batteries 1 are closed. The second charging contactor 10 is open, as are the two main contactors 5 leading to the vehicle connections 2, 3. The batteries 1 are thus connected to the charging station in a series circuit. The batteries 1 of the electric vehicle are thereby charged with 800V.

[0027] In Fig. 4, a second option for charging the battery 1 of the electric vehicle is shown. In this case, the first charging contactor 9 and the second charging contactor 10 are both closed. All three main contactors 5 are open. Thus, several batteries 1 are connected to the charging station in a parallel circuit. The battery 1 of the electric vehicle is thereby charged with 400V.

[0028] As can be seen from figures 1 to 4, in an electric vehicle several contactors are required in order to be able to charge the battery 1 in different networks or charging stations and to connect the battery 1 to the drive of the electric vehicle, i.e. the electric motor. In figures 1 to 4 seven contactors are provided: three main contactors 5, two first charging contactors 9 and two second charging contactors 10. In other applications more or fewer contactors may be provided, for example 5 to 9 contactors.

[0029] In order to save installation space and simplify assembly, the contactors of the electric vehicle, i.e. the main contactor 5, the first charging contactor 9 and the second charging contactor 10, are each configured as a contactor module and arranged in a modular contactor box 13. The modular contactor box 13 is shown in FIG. 5. By contactor module, it is meant that a number of contactors are configured as identically as possible or contain as many identical components as possible, so that they can be produced cost-effectively. 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 has a module housing 14, which will be described in more detail below with reference to FIG. 6. The contactor modules are inserted into the module housing 14. In order to minimize electrical losses, the required space and costs, at least two of the contactor modules arranged in the contactor box are connected to each other internally, i.e. within the contactor box 13. This will be described in more detail below with reference to FIGS. 6 to 8. Each contactor module has at least two contactor module connection contacts. The contactor module connection contacts are contacts (contacts, terminals) to which each contactor module 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 a number of coil connections 16. Each coil connection 16 can be routed outward through the module housing 14 and connected together via a printed circuit board / lead frame 17. The coils of the individual contactor modules can be controlled individually. In addition, a contactor box connection contact 18 is shown in FIG. 5. The modular contactor box 13 can also have a number of contactor box connection contacts. The maximum number of contactor box connection contacts is always at least one less than the number of contactor module connection contacts of all contactor modules arranged in the contactor box. In addition, the modular contactor box 13 may have a control assembly 15 that is attached to the module housing 14.5 shows three possible mounting locations for the control assembly 15. For example, the control assembly 15 can be located on one of the side walls of the module housing 14. However, it is also contemplated that the control assembly 15 can be mounted on a printed circuit board / lead frame 17.

[0030] Figure 6 shows the module housing 14 of the modular contactor box 13 of Figure 5. The module housing 14 is configured as a compartment housing. This means that the module housing 14 has multiple compartments or storage locations 19. Eight storage locations 19 are shown in Figure 6. Each storage location 19 is configured to allow a contactor module to be easily inserted and latched.

[0031] 7 exemplarily illustrates a contactor module 20 for use in the modular contactor box 13 of FIG. 5. At least the outer dimensions of all the contactor modules 20 that can be inserted into the contactor box 13 are preferably configured to be identical. However, it is also possible that a number of or all of the contactor modules 20 have a completely identical structure. Each contactor module 20 has a contactor housing 21. The contactor housing 21 and the receiving positions 19 of the module housing 14 match each other, so that each contactor housing 21 can be easily inserted into each of the receiving positions 19 of the module housing 14 and preferably plugged in.

[0032] An electromagnetic drive with a coil 22 is arranged in the contactor housing 21. A contactor bridge 23 is displaceable by the electromagnetic drive. Two movable contacts 24 are formed on the contactor bridge 23. Each movable contact 24 interacts with one fixed contact. Each fixed contact is connected to a contactor module connection contact. The fixed contacts may also be formed in the contactor module connection contact or be integrally connected thereto (not shown).

[0033] 8 is a plan view of the module housing 14 with a plurality of contactor modules 20 disposed therein. As described above, the module housing 14 has eight receiving positions 19 each receiving one contactor module 20. Contactor modules 20 are inserted into six of the plurality of receiving positions 19. Two receiving positions 19 are empty. The contactor modules 20 are configured according to the embodiment shown in FIG. 7. Additionally, each contactor module 20 has two fixed contacts that interact with two movable contacts 24 disposed on a contact bridge 23.

[0034] As can be clearly seen from Fig. 8, two of the contactor modules 20 are connected to each other internally, i.e. in the contactor box 13. For this purpose, connecting members 25 are provided. Two fixed contacts are formed in each of the connecting members 25, which are assigned to two different contactor modules 20. The connecting members 25 form one contactor module connecting contact for each of the contactor modules 20 that they connect. If one connecting member connects two contactor modules, this connecting member forms two contactor module connecting contacts.

[0035] The connection members 25 can be configured as bus bars. In addition, each of the connection members 25 has a contactor box connection contact 18 facing outward. The contactor box connection contact 18 can be configured as a contact lug or a contact pill 26. The other fixed contacts of the respective contactor module 20 are also formed in the bus bar to form the contactor module connection contacts. In the case of the configuration shown in FIG. 8, the contactor module connection contacts that are not formed in the connection members 25 are integrated into the contactor box connection contact 18. The contactor box connection contact 18 has a convex contact 26 that extends outward from the module housing 14 and allows for an external connection. As can be seen from FIG. 8, the two upper connection members 25 are configured in a substantially Z-shape. The connection member 25 at the bottom of FIG. 8 is F-shaped and bridges the fixed contact / bus bar located below it. It is also possible to configure the connection members as multiple bridges to connect more than two contactor modules to each other.

[0036] At least one fixed contact of the contactor module may have a groove transverse to the closing direction of the contacts of the contactor module, the groove side being at least partially oblique to the closing direction so as to form an angle not equal to 90° with respect to the closing direction, and the movable contact of the contactor module is configured such that a contact point present in the closed position of the contacts of the contactor module between the fixed contact and the movable contact occurs at the obliquely running groove side.

[0037] Furthermore, the fuses or pyro switches shown in Figures 1 to 4 may be built into the contactor box. The contactor box may include a plug-type interface. Sensors for measuring current and tap points for measuring voltage may be disposed within the module housing.

[0038] In addition, at least one extinguishing area may be formed in the module housing to extinguish the electric arcs that occur during the switching operation of the contactor module. The pressure drop when the contactor module is switched off occurs relatively quickly according to Paschen's law, so that a small volume of the extinguishing area is sufficient. This allows the required installation space to be reduced. To further reduce the volume of the contactor box, the extinguishing area may be assigned to at least two contactor modules. [Explanation of symbols]

[0039] 1 Battery 2, 3 Vehicle connection part 4 Vehicle connection line 5 Main Contactor 6 Charging connection wire 7, 8 Charging connector 9 First charging contactor 10 Second charging contactor 11. Fuse 12 Pyro Switch 13 Contactor Box 14 Module housing 15 Control Assembly 16 Coil connection 17 Printed Circuit Boards / Lead Frames 18 Connection contact 19 Plug-in Points 20 Contactor Module 21 Contactor housing 22 Coil 23 Contact Bridge 24 Movable contact 25 Connection parts 26 Convex contact part

Claims

1. A modular contactor box (13), in particular for electric vehicles, comprising: The contactor box (13) comprises: a module housing (14) having a number of receiving locations (19) each receiving one contactor module (20); at least two contactor modules (20), each having at least two contactor module connection contacts and each accommodated in one of the accommodation locations (19) of said module housing (14); - at least two contactor box connection contacts (18); having At least two of the contactor modules (20) are interconnected with each other such that the maximum number of the contactor box connection contacts (18) is at least one less than the number of the contactor module connection contacts. A contactor box (13).

2. The contactor box (13) according to claim 1, The contactor modules (20) interconnected with each other are connected to each other via a common connecting member (25) forming a fixed contact. A contactor box (13).

3. 3. The contactor box according to claim 1, More than two contactor modules are preferably interconnected with each other by a common connecting member configured as a multiple bridge. A contactor box comprising:

4. In the contactor box (13) according to any one of claims 1 to 3, The contactor module (20) is pluggable into the receiving location (19). A contactor box (13).

5. A contactor box (13) according to any one of claims 1 to 4, Each contactor module (20) has at least one moving contact and at least one fixed contact; the at least one fixed contact of the at least one contactor module (20) has a groove transverse to a closing direction of the contacts of the at least one contactor module (20), the groove side of the groove being at least partially oblique to the closing direction so as to form an angle not equal to 90° with respect to the closing direction; The at least one movable contact (24) of the at least one contactor module (20) is configured such that, in a closed position of the contacts of the at least one contactor module (20), a contact point between the fixed contact and the movable contact occurs on the obliquely extending groove side surface. A contactor box (13).

6. In the contactor box (13) according to any one of claims 1 to 5, At least one arc-extinguishing area is formed within the module housing for extinguishing an electric arc that occurs during a switching operation of the contactor module. A contactor box (13).

7. A contactor box (13) according to claim 6, The at least one extinguishing area is assigned to at least two contactor modules (20). A contactor box (13).

8. In the contactor box (13) according to any one of claims 1 to 7, At least one fuse is disposed within the module housing (14). A contactor box (13).

9. In the contactor box (13) according to any one of claims 1 to 8, At least one pyroswitch is disposed within the module housing (14). A contactor box (13).

10. In the contactor box (13) according to any one of claims 1 to 9, Further features include plug-in interfaces A contactor box (13).

11. In the contactor box (13) according to any one of claims 1 to 10, A sensor for measuring current is disposed within the module housing. A contactor box (13).

12. A contactor box (13) according to any one of claims 1 to 11, A tap point for measuring voltage is located within the module housing. A contactor box (13).

13. In the contactor box (13) according to any one of claims 1 to 12, At least one of the contactor modules (20) has a coil (22) that drives a movable contact (24); The coil (22) has a plurality of coil connections (16), All of the coil connections (16) are located in the module housing (14) and can be connected together. A contactor box (13).

14. A contactor box (13) according to any one of claims 1 to 13, and a common control assembly (15) disposed in the module housing (14). A contactor box (13).

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