Switching Devices and Energy Storage Systems

Abstract

The switching device (100) comprises a fixed busbar mechanism having at least a pair of fixed input busbars (140, 142) and a pair of fixed output busbars (144, 146), a movable busbar mechanism having at least one connecting busbar (130, 132), and at least one actuating element (117) for changing the position of the movable busbar mechanism at least to a first switching position, from the first switching position, to a second switching position, and from the second switching position, wherein in the first switching position, the fixed input busbars (140, 142) are each electrically connected to one of the fixed output busbars (144, 146), and in the second switching position, the pair of fixed input busbars (140, 142) are electrically connected to each other, and the movable busbar mechanism is rotated by the at least one actuating element (117) for changing the position of the movable busbar mechanism.

Description

[Technical Field]

[0001] The present invention relates to a switching device capable of switching the connection state of at least two batteries of a high-voltage energy storage system between a series connection and a parallel connection, and to an energy storage system including the switching device.

[0002] With the development of battery-powered vehicles, such as electric vehicles (EVs) or hybrid electric vehicles (HEVs), high-voltage energy storage systems have become widely used in vehicles. Recently, such high-voltage energy storage systems have typically been capable of providing voltages ranging from 400 V to 1 kV or even higher. In these high-voltage systems, a known technique involves the use of contactor devices to connect and disconnect electronic circuits within the energy storage system.

[0003] Conventionally, contactor devices can be reversibly switched between a closed state, in which current flows through the contactor device, and an open state, in which current is interrupted. Furthermore, it is known to use overcurrent protection devices, such as pyrofuses, to irreversibly interrupt the voltage supply in high-voltage energy storage systems. This is necessary, for example, when an excessive overcurrent or a fault is detected in the electronic circuitry of the energy storage system, or when a vehicle powered by power supplied from the energy storage system is involved in an accident.

[0004] However, depending on the application of the energy storage system, it may be desirable to provide more switching states. In particular, high-voltage drive batteries that supply voltages of around 800V are increasingly being used in battery-powered vehicles. To provide such high voltages, a high-voltage battery is formed by electrically connecting multiple battery modules (or battery packs). However, because 400V has traditionally been used as the output voltage of the drive battery, many chargers or charging stations can only supply charging voltages up to 400V, and are particularly unable to supply charging voltages of around 800V. To solve this problem, a known technology involves electrically connecting two high-voltage drive batteries (or battery strings), each with an output voltage of 400V, in parallel during charging, and electrically connecting the batteries (or battery strings) in series during driving to output an output voltage of 800V.

[0005] However, when the above-mentioned single-pole contactor device is used, at least three contactor devices are required to selectively electrically connect two batteries (or battery strings) in parallel or in series. Therefore, a new switching device is needed that can simplify the configuration for selectively electrically connecting two batteries (or battery strings) in parallel or in series.

[0006] For example, DE10 2021 104 142 A1 discloses a switching device having a contact mechanism with a first contact element and a second contact element for selectively bridging the interruption of two switching paths of the switching device, the contact mechanism being moved by an actuator to switch the switching device between a first switching state in which two batteries can be connected in series and a second switching state in which two batteries can be connected in parallel.

[0007] However, conventional switching devices have a problem in that the contact mechanism is complicated, resulting in an increase in the weight of the device. The inventors of the present invention have found room for improvement in conventional switching devices.

[0008] Therefore, it is an object of the present invention to provide a switching device that can change the connection state of a high-voltage battery using a simplified contact mechanism, and to provide a solution that is space-saving, lightweight, and cost-effective.

[0009] This object is achieved by the invention according to the independent claims. Advantageous aspects of the present disclosure are the inventions according to the dependent claims.

[0010] According to a first aspect of the present disclosure, there is provided a switching device comprising: a fixed busbar mechanism having at least a pair of fixed input busbars and a pair of fixed output busbars; a movable busbar mechanism having at least one connecting busbar; and at least one actuating element for changing a position of the movable busbar mechanism to, from, to, and from at least a first switching position, wherein, in the first switching position, each of the fixed input busbars is electrically connected to one of the fixed output busbars; and, in the second switching position, the pair of fixed input busbars are electrically connected to each other; and the movable busbar mechanism is rotated by the at least one actuating element for changing a position of the movable busbar mechanism.

[0011] The present disclosure provides a switching device for switching between two output voltage levels with a more efficient contact mechanism by introducing rotational motion of the movable busbar mechanism. This allows for a significant reduction in the weight and space required of the switching device compared to conventional configurations. Furthermore, the reduction in the number of contacts reduces contact resistance in the switching path of the switching device, essentially preventing short circuits. This improves mechanical safety and reduces the risk of arcing. Here, rotation of the movable busbar mechanism specifically refers to a rotation that changes only the orientation of the entire movable busbar mechanism, without changing the arrangement of the connecting busbars of the movable busbar mechanism.

[0012] According to a second aspect, in addition to the first aspect, the present invention further includes a transmission unit including at least one driven member and at least one output member coupled to each other so as to be rotatable within a first angular range, wherein the movable busbar mechanism is supported on the at least one output member, and the driven member is rotated by the at least one actuating element to change the position of the movable busbar mechanism.

[0013] By implementing a transmission unit for transmitting the force generated by the at least one actuating element to the movable busbar mechanism, the switching device allows efficient force transmission for rotational movement of the movable busbar mechanism between switching positions.

[0014] According to a third aspect, in addition to the second aspect, the rotational movement of the at least one output member is limited to the first angular range. This enables the third aspect to accurately position the movable busbar mechanism at the first switching position and the second switching position. According to a fourth aspect, in addition to the second or third aspect, when the at least one driven member is driven outside the first angular range and the at least one output member moves the movable busbar mechanism along a direction at least substantially parallel to the rotation axis of the driven member, the at least one driven member applies an axial force to the at least one output member.

[0015] According to the fourth aspect, torque transmitted to at least one driven member can be converted into an axial force, and the torque can be efficiently transmitted and used to move the movable busbar mechanism by linear motion along a direction parallel to the rotation axis of the driven member. This reduces friction at the contact points of the fixed busbar and the movable connecting busbar. Alternatively, a first dedicated actuator may be provided to generate torque to rotate the movable busbar mechanism, and a second dedicated actuator may be provided to linearly move the movable busbar mechanism so that it comes into contact with the fixed busbar mechanism.

[0016] According to a fifth aspect, in addition to any one of the second to fourth aspects, the at least one output member includes a toothed hub shape that conforms to and rotatably engages with a mating notch shape of the at least one driven member within the first angular range, and disengages from the toothed hub shape when the at least one driven member is driven outside the first angular range. This improves torque transmission efficiency between the at least one driven member and the at least one output member within the first angular range. Furthermore, outside the first angular range, the at least one driven member is prevented from applying torque to the at least one output member, allowing the transmission unit to efficiently transmit force generated by the at least one actuating element.

[0017] According to a sixth aspect, in addition to the fifth aspect, the toothed hub is formed as an inclined wedge, which makes it possible to decouple the at least one output member from the at least one driven member with reduced friction when the at least one driven member is driven outside the first angular range.

[0018] According to a seventh aspect, in addition to any one of the second to sixth aspects, the at least one driven member is mechanically connected to a shaft structure, and the shaft structure transmits to the at least one driven member a torque generated by the at least one actuating element for changing a position of the movable busbar mechanism, wherein the torque can be transmitted from the at least one actuating element to the shaft structure via a gear, and the gear can define an optimum gear transmission ratio for driving the shaft structure.

[0019] According to an eighth aspect, in addition to any one of the second to seventh aspects, the housing of the switching device includes at least one output member blocking element configured to engage with at least one protrusion of the at least one output member to limit rotational movement of the at least one output member to the first angular range. Alternatively, or in addition, the housing includes at least one driven member blocking element configured to engage with at least one protrusion of the at least one driven member to limit rotational movement of the at least one driven member to a second angular range greater than the first angular range. Each such blocking element limits the range of movement of the at least one driven member and the at least one output member, thereby improving the efficiency of force transmission from the at least one actuating element to the movable busbar mechanism. Forming the blocking element integrally within the housing of the switching device reduces the space required for the switching device and simplifies the manufacturing process. However, without being limited thereto, the blocking element may be provided as a dedicated component and disposed within the switching device separately from the housing.

[0020] According to a ninth aspect, in addition to the eighth aspect, the at least one output member blocking element comprises at least one asymmetrically formed guide groove, which is designed to limit movement of the at least one output member to axial movement when the at least one driven member is driven outside the first angular range, thereby allowing the movable contact mechanism to linearly lower or raise when closing or opening contact between the movable contact mechanism and a fixed busbar of the switching device.

[0021] According to a tenth aspect, in addition to any one of the second to ninth aspects, the at least one connecting busbar of the movable busbar mechanism is elastically supported on the at least one output member by at least one bias spring element. This has the advantage that it is possible to control the contact force between the movable busbar mechanism and the fixed busbar when the at least one output member presses the at least one movable busbar against the fixed busbar mechanism. Furthermore, the at least one bias spring element also contributes to absorbing small misalignments or imbalances between the connecting busbars of the movable busbar mechanism.

[0022] According to an eleventh aspect, in addition to the above aspects, the movable bus bar mechanism includes a first connection bus bar and a second connection bus bar, and in the first switching position, the first connection bus bar and the second connection bus bar each electrically connect one of the fixed input bus bars to one of the fixed output bus bars, thereby enabling the movable bus bar mechanism to connect two batteries in parallel using a low-resistance connection with only two contacts per connection path.

[0023] According to a twelfth aspect, in addition to the eleventh aspect, in the second switching position, the first connection busbar electrically connects the pair of fixed input busbars to each other, the second connection busbar is electrically connected to at most one of the fixed input busbars or one of the fixed output busbars, and at least one contact of the second connection busbar is electrically isolated from the remaining busbars of the fixed busbar mechanism. This allows the first connection busbar of the movable busbar mechanism to connect two batteries in series through a low-resistance connection via only two contacts, while the second connection busbar is not involved in the electrical connection. For example, by providing a sufficient gap between the first connection busbar and the other busbars of the fixed busbar mechanism, at least one contact of the second connection busbar is electrically isolated, thereby preventing short circuits and arcs from occurring within the switching device.

[0024] According to a thirteenth aspect, in addition to each of the above aspects, the switching device further includes a first connection terminal electrically connected to one side of the fixed input bus bar and electrically connecting a first battery, and a second connection terminal electrically connected to the other side of the fixed input bus bar and electrically connecting a second battery.

[0025] According to a fourteenth aspect, in addition to the above aspects, the at least one actuating element includes an electric motor configured to rotate the at least one driven member of the transmission unit to change the position of the movable busbar mechanism. Alternatively, or in addition to the fourteenth aspect, the force generated by the at least one actuating element to change the position of the movable busbar mechanism is transmitted by a worm gear. This ensures that the switching device consumes power only when its position is changed and that the position of the switching device does not change when the electric motor is de-energized. This allows the switching device to provide two stable states, and even if the power supply to the at least one actuating element is suddenly lost due to, for example, the occurrence of a single point of failure, other damage, or a communication error, the contactor device maintains its previous state. Furthermore, the worm gear ensures that the movable busbar mechanism is locked in the first or second switching position. Furthermore, the gear transmission ratio of the worm gear enables efficient force transmission from the at least one actuating element to the at least one driven member.

[0026] According to a 15th aspect, a power supply comprises at least a first battery, a second battery, and the above-mentioned switching device, and the first battery and the second battery are electrically connected to the switching device so that the switching device can switch the first battery and the second battery between a series state and a parallel state, the series state being a state in which the first battery and the second battery are electrically connected in series by the switching device, and the parallel state being a state in which the first battery and the second battery are electrically connected in parallel by the switching device.

[0027] Throughout this specification, the term "terminal" refers to a point at which a conductor from an electrical device, electrical circuit, or electrical component terminates and serves to electrically connect the conductor to an external electrical device, electrical circuit, or electrical component. Furthermore, the terms "electrically connected" and "conductively coupled" refer to the establishment of an electrical connection between at least two electrical devices, electrical components, or electrical conductors that allows for the flow of electrical current. This electrical connection is not limited to direct connection between the terminals of at least two electrical devices, electrical components, or electrical conductors, but may also include other electrical devices, electrical components, or electrical conductors.

[0028] The accompanying drawings are incorporated herein and form a part of this specification to illustrate several examples of the present disclosure. These drawings, together with the description, serve to explain the principles of the present disclosure. The drawings are preferred alternative examples of how the present disclosure can be implemented and used, and the present disclosure should not be construed as limited to only the examples shown and described. Furthermore, some aspects of the examples can implement solutions according to the present disclosure individually or in different combinations. Thus, the examples described below can be implemented alone or in any combination thereof. Further features and advantages will become apparent from the following more detailed description of various examples of the present disclosure, as illustrated in the accompanying drawings, in which like references refer to like elements. [Brief explanation of the drawings]

[0029] [Figure 1] FIG. 1 is a circuit diagram illustrating an example of a high-voltage energy storage system. [Figure 2] FIG. 1 is a perspective view schematically illustrating an example of a switching device. [Figure 3] FIG. 2 is a perspective view schematically illustrating an example of a part of an internal component of a switching device. [Figure 4] FIG. 10 is a perspective view schematically illustrating another example of a part of the built-in components of the switching device. [Figure 5]FIG. 10 is a plan view schematically illustrating an example of a switching device in a parallel connection state. [Figure 6] FIG. 10 is a bottom view schematically illustrating an example of a contact mechanism of a switching device in a parallel connection state. [Figure 7] FIG. 1 is a plan view schematically illustrating an example of a switching device in a series connection state. [Figure 8] FIG. 10 is a bottom view schematically illustrating an example of a contact mechanism of a switching device in a series connection state. [Figure 9] FIG. 10 is a plan view schematically illustrating another example of a switching device in a series connection state. [Figure 10] FIG. 2 is a perspective view schematically illustrating an example of a driven member of a transmission unit. [Figure 11] FIG. 10 is a perspective view schematically illustrating an example of an output member of a transmission unit. [Figure 12] FIG. 10 is a plan view schematically illustrating another example of a switching device in a series connection state. [Figure 13] FIG. 1 is a perspective view schematically illustrating an example of a switching device in a series connection state. [Figure 14] 1 is a perspective view schematically illustrating an example of a switching device in a first position in a switching process from a series connection state to a parallel connection state. [Figure 15] FIG. 10 is a perspective view schematically illustrating an example of a switching device in a second position in a switching process from a series connection state to a parallel connection state. [Figure 16] FIG. 10 is a perspective view schematically illustrating an example of a switching device in a third position in a switching process from a series connection state to a parallel connection state. [Figure 17] FIG. 1 is a perspective view schematically illustrating an example of a switching device in a parallel connection state. [Figure 18] FIG. 1 is a cross-sectional view schematically illustrating an example of a switching device. DETAILED DESCRIPTION OF THE INVENTION

[0030] The present invention will now be further described with reference to the drawings. First, reference is made to FIG. 1. FIG. 1 is a circuit diagram that schematically illustrates an example of a high-voltage energy storage system 10 based on the concept of the present disclosure. The energy storage system 10 includes two high-voltage batteries 500(1) and 500(2), which may serve as, for example, drive batteries for a battery-powered vehicle, and a switching device 100. In the following description, it is assumed that the batteries 500(1) and 500(2) each have an output voltage of 400 V, but other output voltages may also be used. Typically, the batteries 500(1) and 500(2) each include multiple battery modules or battery packs, which are further configured with multiple battery cells connected in series and / or parallel. In general, the number of high-voltage batteries 500 provided in the energy storage system 10 is not limited to two, and more batteries may also be used.

[0031] The switching device 100 includes input terminals 102 and 104. The input terminal 102 is configured to be electrically connected to a high-potential side (+) terminal 502 of the battery 500(2). The input terminal 104 is configured to be electrically connected to a low-potential side (-) terminal 504 of the battery 500(1). The switching device 100 further includes output terminals 106 and 108 configured to be electrically connected to a high-voltage bus 506, which is electrically connected to, for example, the drive train of a battery-powered vehicle or a charger (or charging station) for charging the high-voltage batteries 500(1) and 500(2). The output terminal 106 is electrically connected to the high-potential side (+) of the high-voltage bus. The high side (+) of the high voltage bus is electrically connected to the high side (+) terminal 508 of battery 500(1) by node 512, and therefore output terminal 106 is also electrically connected to the high side (+) terminal 508 of battery 500(1). Output terminal 108 is electrically connected to the low side (-) of the high voltage bus. The low side (-) of the high voltage bus is electrically connected to the low side (-) terminal 510 of battery 500(2) by node 514, and therefore output terminal 108 is also electrically connected to the low side (-) terminal 510 of battery 500(2).

[0032] The switching device 100 is configured to switch the first battery 500(1) and the second battery 500(2) between a series connection state in which they are electrically connected in series by the switching device 100 and a parallel connection state in which they are electrically connected in parallel. Therefore, in the series connection state, the voltage difference between the high potential side (+) and the low potential side (-) of the high voltage bus 506 is substantially equal to the sum of the voltages supplied by the first battery 500(1) and the second battery 500(2) (e.g., 400V + 400V = 800V). On the other hand, in the parallel connection state, the voltage difference between the high potential side (+) and the low potential side (-) of the high voltage bus 506 is substantially equal to the voltages supplied individually by the first battery 500(1) and the second battery 500(2) (e.g., 400V). In this manner, switching device 100 can switch the voltage applied to high voltage bus 506 between a first low voltage level, e.g., equal to the charging voltage to batteries 500(1), 500(2), and a second high voltage level, e.g., equal to the operating voltage of a battery-powered vehicle.

[0033] FIG. 2 is a perspective view schematically illustrating an example of a switching device 100. The switching device 100 includes a housing 110, from which input terminals 102, 104 and output terminals 106, 108 protrude. For example, the housing may be composed of two parts: a housing base 112 and a housing cover 114. For example, the housing 110 may be a sealed housing. In this case, a vacuum or an electronegative gas may be provided within the space enclosed by the housing 110, thereby preventing sparks or arcs from occurring when the switching device 100 is switched. In the illustrated example, the input terminals 102, 104 and the output terminals 106, 108 are formed as notches, which can be screwed to the respective external electrical components, such as terminal clamps of the battery 500(1) or 500(2) or bus bars electrically connected to the switching device 100. Alternatively, the input terminals 102, 104 and the output terminals 106, 108 may be formed as welded or soldered joints, for example. In this case, the switching device can be welded or soldered to the external electrical component.

[0034] In the illustrated example, the housing 110 accommodates an electric motor 117 as an actuating element that generates a transmission force to switch the state of the switching device 100. To connect the electric motor 117 to a controller of the switching device 100, the electric motor 117 can be connected to a motor connection pin 115 that protrudes from the switching device housing 110. Alternatively, the electric motor 117 can be any other actuating element known in the art of high-voltage switching devices, such as an electromagnetic actuator.

[0035] 3 and 4 are perspective views schematically illustrating some of the internal components of the switching device 100. As shown in the figures, a housing 110 of the switching device accommodates a fixed contact mechanism and a movable bus bar mechanism. In the illustrated configuration, the fixed bus bar mechanism includes a pair of input bus bars, namely, a first input bus bar 140 and a second input bus bar 142, and a pair of output bus bars, namely, a first output bus bar 144 and a second output bus bar 146. The input bus bars 140 and 142 are electrically connected to one of the input terminals 102 and 104, respectively. In the illustrated example, the input bus bars 140 and 142 are connected by being integrally formed with the respective input terminals. The output bus bars 144 and 146 are electrically connected to one of the output terminals 106 and 108, respectively. In the illustrated example, the output bus bars 144 and 146 are electrically connected to one of the output terminals 106 and 108, respectively. In the illustrated configuration, the movable bus bar mechanism, which is movable to change the state of the switching device 100, includes a first connecting bus bar 130 and a second connecting bus bar 132 (see FIG. 4). As will be described below, the first connecting bus bar 130 and the second connecting bus bar 132 are configured to electrically connect the respective bus bars of the fixed bus bar mechanism according to the desired connection state of the switching device 100.

[0036] It should be noted that, depending on the application, the number of fixed bus bars and the number of movable connecting bus bars may be other than those shown in the example shown. For example, the switching device 100 may be electrically connected to three or more batteries (or battery strings) 500.

[0037] In the illustrated example, when the position of the movable bus bar mechanism is changed, a force generated by the electric motor 117 is transmitted to the movable bus bar mechanism by a transmission unit 116. The transmission unit 116 includes a shaft 118 with a fixedly mounted drive gear 120. The drive gear 120 meshes with a worm 122 to form a worm gear. The worm gear is driven by the electric motor 117. While the worm gear is not necessarily provided in the switching device 100, it has the advantage of transmitting torque generated by the electric motor 117 to the shaft 118 at an optimal transmission ratio compared to a case in which the electric motor 117 and the shaft 118 are directly mechanically connected without a gear transmission mechanism. Furthermore, the provision of the worm gear prevents transmission of force in the reverse direction via the worm gear, thereby preventing rotation from being transmitted from the shaft 118 to the electric motor 117 when the electric motor 117 is de-energized. Therefore, by transmitting the force via the worm gear, the switching device 100 can have a self-holding function, and power only needs to be supplied to the electric motor 117 when changing the switching position of the switching device.

[0038] In order to selectively convert the force generated by the electric motor 117 into linear or rotational movement of the movable busbar mechanism, the transmission unit 116 includes a driven member 124 that supports the movable busbar mechanism and an output member 128. This makes it possible to advantageously selectively drive the linear or rotational movement of the movable busbar mechanism of the switching device 100 by a predetermined mechanical cooperation between the driven member 124 and the output member 128, which will be described later.

[0039] The driven member 124 is fixedly attached to the shaft 118, for example, by integrally forming the driven member 124 on the shaft 118. The driven member is thereby mechanically coupled to the drive gear 120 by the shaft 118. In this manner, the shaft 118 transmits torque from the drive gear 120 to the driven member 124 when powering the electric motor 117 to change the position of the switching device 100. In the illustrated example, the driven member 124 is formed as a disk-shaped member with a protruding arm 126, the function of which will be described below. Alternatively, the driven member 124 may have another outer shape, or two or more driven members may be attached to the shaft 118 and cooperate with the output member 128 (or two or more output members).

[0040] The output member 128 is rotatably mounted on the shaft 118 adjacent to the driven member 124. The shaft thereby defines a rotation axis for the driven member 124 and the output member 128. In the illustrated example, the output member 128 is configured as a disk-shaped member. The output member 128 may have a different outer shape, and two or more output members may be coupled to the shaft 118 to cooperate with the driven member 124 (or multiple driven members). The output member 128 is axially fixed to the shaft 118 by a return spring 129. Preferably, the return spring 129 is threadedly fastened to the shaft 118 and allows linear movement of the output member 128 along the extension direction (also referred to as the axial direction) of the shaft 118. This will be discussed later.

[0041] As shown in the example of FIG. 4, the output member 128 includes a pair of mating half-shells, including a lower half-shell 134 that supports the movable bus bar mechanism and an upper half-shell 136 that overlays the lower half-shell 134 to form the housing of the output member 128. Alternatively, the housing of the output member 128 may be formed from a single piece, with the connection bus bars attached to the output member 128, for example, during a molding process. For illustrative purposes, the upper half-shell 136 of the output member 128 is shown in dashed lines in FIG. 3, thereby indicating that the first and second connection bus bars 130 and 132 are located in bus bar receiving portions 139 of the output member 128. Additionally, a preloaded spring element 138 is disposed within the output member 128 to resiliently support the connection bus bars 130 and 132 within the output member 128. This allows for better control of the contact force between the connecting busbars 130, 132 and the fixed busbars of the switching device 100 when the output member 128 presses the movable busbar mechanism into contact with the fixed busbar mechanism. Additionally, the preloaded spring elements 138 also help absorb minor misalignments or imbalances between the connecting busbars 130, 132 in the movable busbar mechanism.

[0042] 5 and 6 schematically illustrate the parallel connection state of the switching device 100. FIG. 5 is a plan view schematically illustrating the switching device 100 without the housing cover 114, showing the positions of the individual components of the transmission unit 116 in the parallel connection state. FIG. 6 is a bottom view schematically illustrating the fixed contact mechanism and the movable contact mechanism for explaining the position of the movable busbar mechanism in the parallel connection state. As shown, in the parallel connection state, the movable busbar mechanism is in a first switching position, and the first input busbar 140 is electrically connected to the first output busbar 144 by the first connecting busbar 130. Also, in the first switching position, the second input busbar 142 is electrically connected to the second output busbar 146 by the second connecting busbar 132. Therefore, in the parallel connection state, the switching device 100 electrically connects two batteries connected to the input terminals 102, 104 in parallel (e.g., in the high-voltage energy storage system 10 of FIG. 1).

[0043] 7 and 8 schematically illustrate the switching device 100 in a series-connected state. FIG. 7 is a top view of the switching device 100 without the housing cover 114, illustrating the positions of the individual components of the transmission unit 116 in the series-connected state. FIG. 8 is a bottom view of the switching device 100 in a series-connected state, illustrating the fixed contact mechanism and the movable contact mechanism, and illustrating the positions of the connecting busbars 130 and 132 in the series-connected state. As shown, in the series-connected state, the movable busbar mechanism is in the second switching position, and the first input busbar 140 and the second input busbar 142 are electrically connected to each other by the first connecting busbar 130. Therefore, in the series-connected state, the switching device 100 electrically connects the two batteries connected to the input terminals 102 and 104 in series.

[0044] In the series connection, the first connection bus bar 130 is in electrical contact with both input bus bars 140, 142, and the second connection bus bar 132 is in electrical contact with at most one of the remaining fixed bus bars. In particular, in the illustrated configuration, the second connection bus bar 132 is in electrical contact with the second output bus bar 146. The free contact 148 of the second connection bus bar 132 is electrically isolated from the remaining fixed bus bars. In particular, in the illustrated configuration, the second connection bus bar 132 is electrically isolated from the input bus bars 140, 142 and the first output bus bar 144 by a distance sufficient to prevent arcing or other short circuits. Note that the attachment of the connection bus bars 130, 132 to the rotatable output member makes it particularly easy to ensure the necessary spacing between the free contact 148 of the second connection bus bar 132 and the remaining fixed bus bars. Although not required, additional insulating elements may be provided to ensure insulation between the free contact 148 of the second connection bus bar 132 and the remaining fixed bus bars, thereby increasing the safety and reliability of the switching device 100.

[0045] To move the movable busbar mechanism between the first and second switching positions, the movable busbar mechanism is rotated in a plane parallel to the extension direction of the connecting busbars 130, 132 of the movable busbar mechanism. Here, the shaft 118 functions as the axis of rotation. This means that rotation of the movable busbar mechanism changes only the orientation of the entire movable busbar mechanism, without changing the relative alignment of the connecting busbars 130, 132 with respect to one another. Therefore, rotation of the movable busbar mechanism does not, for example, cause the connecting busbars 130, 132 to tilt or twist relative to one another.

[0046] To rotate the movable bus bar mechanism, an output member 128, to which first and second connecting bus bars 130, 132 are attached, is rotatably drivingly coupled to driven member 124 within a first angular range. Thus, output member 128 rotates about its axis of rotation, which corresponds to the axis of rotation of driven member 124 and is defined by shaft 118.

[0047] As shown in FIG. 9 , the degree of freedom of rotational movement of the output member 128 is limited to a first angular range by protrusions 158 protruding from the circular base of the output member 128. These protrusions 158 engage with wall members 156 of the switching device, which function as output member blocking elements. The wall members 156 extend, particularly from the housing base 112, upward from the base of the housing 110 and circumferentially surround the output member 128. The inner radius of the wall members 156 is designed to be smaller than the radius of the output member 128 where the protrusions 158 are located. When the protrusions 158 reach the boundary of the first angular range, the protrusions 158 abut against and engage with the wall members 156, thereby stopping the rotational movement of the output member 128 in either the clockwise or counterclockwise direction. FIG. 9 shows the boundaries of the first angular range diagrammatically by dotted lines 150 and 152, which indicate the positions where the protrusions 158 engage with the wall member 156 (for convenience of illustration, only one of the protrusions 158 is shown). The dotted lines 150 and 152 enclose the first angular range as a range of movement I of the output member 128, more specifically, as a range of movement in which the rotational movement of the output member 128 is permitted by the protrusions 158. The direction in which the output member 128 can move within the first angular range is diagrammatically indicated by arrow 154. The height of the middle portion 157 of the wall member 156 is set lower within the first angular range than the height of the other portions of the wall member 156 so that the output member 128, and in particular its protrusion 158, can rotate within the first angular range.

[0048] In the illustrated example, the wall member 156 is provided as a single piece integrally formed with the base of the housing 110. However, this is by way of example only, and the wall member 156 may be comprised of multiple separate pieces and may be located within the switching device 100 separate from the housing 110. Furthermore, in the illustrated example, two protrusions 158 are provided on the output member 128. However, depending on the application, other numbers of protrusions 158 may be provided and the design of the wall member 156 (or other output member blocking element) may be modified accordingly.

[0049] As described above, the output member 128 is rotationally drivingly coupled to the driven member 124 when at least the driven member 124 drives the rotational movement of the output member 128 within a first angular range to rotate the output member 128. This allows the driven member 124 to transmit torque generated by the electric motor 117 to the output member 128, causing it to rotate within the first angular range. To couple the output member 128 to the driven member 124 within the first angular range, the driven member may have a plurality of notches 160 (see FIG. 10 ), at least one notch 160, on its underside, thereby forming a notch shape. The output member 128 may have a plurality of hubs 162 (see FIG. 11 ), at least one hub 162, on its upper side, i.e., opposite the connection busbars 130, 132, thereby forming a mating hub shape that can mate with the notch shape of the driven member. For optimal torque transmission, it is desirable that the number of hubs 162 correspond to the number of notches 160, and that the hubs 162 be geometrically matched and fitted to the notches 160. However, other configurations may be used depending on the application.

[0050] While the configuration in which the movable busbar mechanism rotates between the first and second switching positions offers many advantages, such as reducing the overall weight of the switching device 100, a problem with purely rotating the movable busbar mechanism is that it increases friction with the contact elements disposed at the contact points of the busbar mechanism, making the contact elements more susceptible to damage. The contact elements are sensitive structures, such as silver buttons made of silver or a silver alloy, or other suitable conductive materials, which effectively reduce contact resistance in series and parallel connection states. Therefore, damage to the contact elements can significantly degrade the performance of the switching device 100.

[0051] Therefore, in order to reduce friction on the contact elements when opening the contacts between the movable contact mechanism and the fixed contact mechanism, it is desirable that the movable busbar mechanism be separated from the fixed busbar of the fixed busbar mechanism by linear motion before the movable contact mechanism is rotated. For example, when opening the contacts of the switching device 100, the movable busbar mechanism is lifted in a direction parallel to the rotation axis of the output member 128 (or the driven member 124) before the movable contact mechanism is rotated. Similarly, when closing the contacts between the movable contact mechanism and the fixed contact mechanism, it is desirable that the movable busbar mechanism be brought into contact with the fixed busbar of the fixed busbar mechanism by linear motion after the movable contact mechanism is rotated. For example, when opening the contacts of the switching device 100, the movable busbar mechanism is pushed down in a direction parallel to the rotation axis of the output member 128 (or the driven member 124) after the movable contact mechanism is rotated.

[0052] Generally, a second dedicated actuating element may be provided in the switching device 100 to linearly move the movable busbar mechanism. This second actuating element generates a force to linearly move the movable busbar mechanism, for example by lifting or depressing the output member 128. However, to simplify the construction of the switching device 100, it is preferred that the linear movement of the movable busbar mechanism is also driven by the electric motor 117, and the transmission unit 116 is configured to convert the torque generated by the electric motor 117 into a linear force to linearly move the movable busbar mechanism.

[0053] Thus, when the driven member 124 is rotated outside a first angular range that limits the rotational movement of the output member 128, the transmission unit 116 converts torque applied to the driven member 124 into an axial force acting on the output member 128 in a direction parallel to the extension direction of the shaft 118. This axial force causes the output member 128 to move toward the fixed contact mechanism. In particular, when the driven member 124 is driven outside the first angular range, the notch 160 of the driven member 124 disengages from the hub 162 of the output member 128 and begins to slide over the hub 162. To enable smooth separation when the hub 162 disengages from the notch 160, the hub 162 is preferably formed as a ramped wedge with a toothed hub shape, and the notch 160 is preferably formed as a corresponding mating shape.

[0054] When disengaged, the output member 128 is moved by the hub 162 in a direction parallel to the extension direction of the shaft 118 due to cooperation between the hub 162 and intermediate regions 168, which are provided between adjacent notches 160 on the driven member 124 and extend higher than the notches 160. Therefore, the maximum axial movement of the output member 128 (and the connection bus bars 130, 132 held by the output member 128) is determined by the maximum height of the hub 162 and the amount of protrusion (relative to the notches 160) of the intermediate regions 168. To utilize the maximum movement to position the connection bus bars 130, 132 on the fixed contact mechanism and to prevent the driven member 124 from undesirably re-engaging with the output member 128 if the driven member 124 is driven outside the first angular range, the rotational movement of the driven member 124 is limited to a second angular range.

[0055] 12, the degree of freedom of rotational movement of the driven member 124 is limited to a second angular range by a protrusion 172 protruding from the protruding arm 126 of the driven member 124. The protrusion 172 cooperates with a wall member 170 that functions as a driven member blocking element. The wall member 170 extends upward from the base of the housing base 112 at least to a height that allows cooperation with the protrusion 172. In this case, the inner radius of the wall member 170 is designed to be smaller than the radius of the driven member 124 at the position of the protrusion 172. When the protrusion 172 reaches the boundary of the second angular range, the protrusion 172 abuts against the wall member 170, stopping the rotational movement of the driven member 124 in either the clockwise or counterclockwise direction, thereby engaging with the wall member 170. 12, the boundaries of the second angular range over which the protrusions 172 engage the wall member 170 are indicated schematically by continuous lines 164, 166 (only one of the protrusions 172 is shown for ease of illustration), and the boundaries of the first angular range are indicated by dashed lines 150, 152. In the example shown, one protrusion 172 is provided on each arm 126 of the driven member 124. However, depending on the application, multiple protrusions 172 per arm 126 or a different number of arms 126 may be provided, and the design of the wall member 170 may be modified accordingly.

[0056] 12 , the rotational freedom of driven member 124, and more specifically, protrusion 172 of driven member 124, is limited less than the rotational freedom of output member 128, and more specifically, protrusion 158 of output member 128. In particular, the second angular range encompasses Region I, in which driven member 124 is rotationally drivingly coupled to output member 128, and also encompasses Region II (between continuous line 164 and dashed line 150) and Region III (between continuous line 166 and dashed line 152), in which driven member 124 applies an axial force to output member 128, changing its height. Arrow 154 schematically indicates the directions in which driven member 124 can move within the first angular range.

[0057] 13 to 17 are schematic perspective views showing the switching device 100 at various points in the switching process when the switching device 100 is switched from a series connection state (FIG. 13) to a parallel connection state (FIG. 17). In order to explain the internal configuration of the switching device 100 during the switching process, particularly the operation of the transmission unit 116, only a portion of the housing 110 of the switching device 100 is shown in FIGS. 13 to 17.

[0058] In the series connection state shown in FIG. 13 , the driven member 124 is displaced clockwise to its maximum extent (as viewed from above the switching device 100), resulting in the protrusion 172 of the driven member 124 abutting against the wall member 170 in the clockwise direction. The output member 128 is also displaced clockwise to its maximum extent, resulting in the protrusion 158 of the output member 128 abutting against the wall member 156 in the clockwise direction. This allows the protrusion 158 to be guided by the first guide groove 174. When the movable bus bar mechanism opens and closes the contact with the fixed bus bar mechanism at the second switching position, the first guide groove 174 engages with the protrusion 158 to limit the movement of the output member 128 to axial movement. The first guide groove 174 is defined by one side of a portion extending over the entire height of the wall member 156 and the other side of the first guide groove 174, which is the side of the intermediate portion 157 of the wall member 156 with a lower height. Therefore, the heights of the side walls of the first guide groove 174 are asymmetric.

[0059] In the series connection state, the hub 162 of the output member 128 disengages from the notch 160 of the driven member, and the output member 128 is maximally displaced in the axial direction away from the driven member 124 (indicated by arrow 176) due to cooperation between the hub 162 and the intermediate region 168 of the driven member 124. As a result, the output member 128 presses the first and second connection bus bars 130, 132 against the fixed bus bar mechanism, and the first and second input bus bars 140, 142 are electrically connected by the first connection bus bar 130 (see FIG. 8 ).

[0060] FIG. 14 shows the switching device 100 in the first position after the electric motor 117 rotates the driven member 124 counterclockwise (as viewed from above) from the series connection state. This position corresponds to travel region II shown in FIG. 12. Although the displacement of the driven member 124 is reduced, the output member 128 is still fully displaced clockwise because the driven member 124 is still driven outside the first angular range. Therefore, the output member 128 has not rotated as compared to the series connection state, and the movable busbar mechanism maintains the same orientation as in the second switching position but is elevated above the fixed busbar mechanism. However, due to the axial return force applied to the output member 128 by the return spring 129 in the direction opposite to the arrow, the hub 162 of the output member 128 has already partially engaged with the notch 160 of the driven member 124. As a result, the connecting bus bars 130, 132 of the movable bus bar mechanism are raised in a linear motion compared to the series connection state shown in Figure 13. In this position, the movement of the output member 128 is restricted to axial linear motion by the intermediate portion 157 of the wall member 156, which engages with the protrusion 158 of the output member 128, until the hub shape of the output member 128 fully engages with the mating notch shape of the driven member 124.

[0061] FIG. 15 shows the switching device 100 in the second position after the driven member 124 has been rotated counterclockwise by the electric motor 117 from the series connection state. This position corresponds to the travel region I shown in FIG. 12 , where the output member 128 is geometrically fitted to the driven member by the geometric fit between the hub and the notch, and is rotatably coupled (see also the cross-sectional view in FIG. 18 ). Therefore, in this position, the movable busbar mechanism is fully raised and in a rotatable position. Torque applied to the driven member 124 is transmitted to the output member 128, causing it to rotate counterclockwise, and the movable busbar mechanism rotates counterclockwise toward the first switching position. Because the output member 128 is sufficiently raised, the protrusion 158 of the output member 128 is not obstructed by the intermediate portion 157 of the wall member 156.

[0062] FIG. 16 shows the switching device 100 in the third position after the driven member 124 is rotated counterclockwise by the electric motor 117 from the series connection state. This position corresponds to the boundary of travel region I, indicated by the dashed line 152 in FIG. 12, where the output member is fully displaced counterclockwise. In this position, the protrusion 158 of the output member 128 abuts against the wall member 156 above the second guide groove 178. The engagement of the protrusion 158 restricts the movement of the output member 128 to the axial direction only. The movable busbar mechanism is already oriented in the same direction as in the first switching position (see FIG. 6), but remains elevated above the fixed busbar mechanism. Because the rotational movement of the output member 128 is restricted, when the driven member 124 is further rotated counterclockwise from this third position, i.e., into travel region III in FIG. 12, the notch 160 begins to disengage from the hub 162. Therefore, when the driven member 124 is further rotated counterclockwise from the third position, the hub 162 of the output member 128 cooperates with the intermediate region 168 of the driven member 124 to exert an axial force on the output member 128, causing the output member 128 to move axially along direction 176.

[0063] 17 shows a state in which the switching device 100 is in the series connection state, the driven member 124 is displaced counterclockwise to its fullest extent, and the protrusion 172 of the driven member 124 abuts against the wall member 170 from the counterclockwise direction. The output member 128 is also displaced counterclockwise to its fullest extent, and the protrusion 158 of the output member 128 abuts against the wall member 156 from the counterclockwise direction. This guides the protrusion 158 along the second guide groove 178, limiting the movement of the output member 128 in the axial direction when the movable bus bar mechanism opens and closes contact with the fixed bus bar mechanism at the first switching position. The second guide groove 178 is defined by a portion extending across the entire height of the wall member 156 on one side and a lower intermediate portion 157 on the other side of the wall member 156, resulting in asymmetrical sidewall heights.

[0064] In the series connection state, the hub 162 of the output member 128 disengages from the notch 160 of the driven member, and the output member 128 is maximally displaced axially away from the driven member 124 (indicated by arrow 176) by cooperation of the hub 162 and the intermediate region 168 of the driven member 124. Thus, in this position, the output member 128 presses the first and second connection bus bars 130, 132 against the fixed bus bar arrangement, so that the first input bus bar 140 is electrically connected to the first output bus bar 144 by the first connection bus bar 130, and the second input bus bar 142 is electrically connected to the second output bus bar 146 by the second connection bus bar 132 (see FIG. 6 ).

[0065] The switching process between the series connection state (FIG. 13) and the parallel connection state (FIG. 17) of the switching device 100 is reversible. That is, switching from the parallel connection state to the series connection state is performed by driving the driven member 124 clockwise by the electric motor 117 in the same manner as described above. [Explanation of symbols]

[0066] 10 Energy Storage System 100 Switching Device 102,104 Input terminals 106,108 output terminal 110 Case 112 Housing base part 114 Housing cover 115 Motor connection pin 116 Transmission Unit 117 (Electric) Motor 118 Shaft 120 Drive gear 122 Warm 124 Driven member 126 Protruding Arm 128 Output member 130, 132 Connection busbars 134, 136 Shell of output member 138 Spring element 139 Busbar receiving section 140, 142 Input busbar 144, 146 Output busbars 148 contacts 156 Wall components 157 Intermediate part of wall member 158 Protrusion of output member 160 notch 162 Hub 168 Intermediate area 170 Wall components 172 Protrusion of driven member 174, 178 Guide groove 500(1), 500(2) High Voltage Battery 502, 504, 508, 510 Battery Terminals 506 High Voltage Bus 512, 514 High voltage bus nodes

Claims

1. a fixed busbar arrangement comprising at least a pair of fixed input busbars (140, 142) and a pair of fixed output busbars (144, 146); a movable busbar mechanism comprising at least one connecting busbar (130, 132); at least one actuation element (117) for moving the movable busbar mechanism at least to, from, and to a first switching position; In the first switching position, each of the fixed input bus bars (140, 142) is electrically connected to one of the fixed output bus bars (144, 146), and in the second switching position, the pair of fixed input bus bars (140, 142) is electrically connected to each other; the movable busbar mechanism is rotated by the at least one actuation element (117) to change the position of the movable busbar mechanism. Switching device (100).

2. a transmission unit (116) including at least one driven member (124) and at least one output member (128) rotatably coupled to each other within a first angular range; the movable busbar mechanism is supported on the at least one output member (128); 2. The switching device (100) of claim 1, wherein the driven member (124) is rotated by the at least one actuating element (117) for changing the position of the movable busbar mechanism.

3. 3. The switching device (100) of claim 2, wherein rotational movement of the at least one output member (128) is limited to the first angular range.

4. 4. The switching device (100) of claim 2 or 3, wherein when the at least one driven member (124) is driven outside the first angular range and the at least one output member (128) moves the movable busbar mechanism along a direction at least substantially parallel to a rotation axis of the driven member (124), the at least one driven member (124) applies an axial force to the at least one output member (128).

5. the at least one output member (128) comprises a toothed hub configuration; The toothed hub shape is Within the first angular range, the at least one driven member (124) is engaged in a rotationally driving manner by conforming to a mating notch shape of the at least one driven member (124); The switching device (100) according to any one of claims 2 to 4, wherein when the at least one driven member (124) is driven outside the first angular range, the engagement between the mating notch shape and the toothed hub shape is released.

6. 6. The switching device (100) of claim 5, wherein the toothed hub (162) is formed as a ramped wedge.

7. the at least one driven member (124) is mechanically connected to the shaft structure (118); The switching device (100) according to any one of claims 2 to 6, wherein the shaft structure (118) transmits torque generated by the at least one actuating element (117) for changing the position of the movable busbar mechanism to the at least one driven member (124).

8. the housing (110) of the switching device (100) comprises at least one output member blocking element (156) configured to engage at least one protrusion (158) of the at least one output member (128) to limit rotational movement of the at least one output member (128) to the first angular range; and / or 8. The switching device (100) of claim 2, wherein the housing (110) comprises at least one driven member blocking element (170) configured to engage with at least one protrusion (172) of the at least one driven member (124) to limit rotational movement of the at least one driven member (124) to a second angular range greater than the first angular range.

9. the at least one output member block element (156) includes at least one asymmetrically formed guide groove (174, 178); 9. The switching device (100) of claim 8, wherein the guide grooves (174, 178) are designed to limit movement of the at least one output member (128) to axial movement when the at least one driven member (124) is driven outside the first angular range.

10. The switching device (100) according to any one of claims 2 to 9, wherein the at least one connecting bus bar (130, 132) of the movable bus bar mechanism is resiliently supported on the at least one output member by at least one bias spring element (138).

11. The movable busbar mechanism comprises a first connecting busbar (130) and a second connecting busbar (132); 11. The switching device (100) of claim 2, wherein in the first switching position, the first connecting busbar (130) and the second connecting busbar (132) each electrically connect one of the fixed input busbars (140, 142) to one of the fixed output busbars (144, 146).

12. 12. The switching device (100) of claim 11, wherein in the second switching position, the first connecting busbar (130) electrically connects the pair of fixed input busbars (140, 142) to each other, the second connecting busbar (132) is electrically connected to at most one of the fixed input busbars (140, 142) or one of the fixed output busbars (144, 146), and at least one contact (148) of the second connecting busbar (132) is electrically isolated from the remaining busbars of the fixed busbar arrangement.

13. a first connection terminal (102) electrically connected to one of the fixed input bus bars (140) and electrically connecting a first battery; a second connection terminal (104) electrically connected to the other of the fixed input bus bars (142) and configured to electrically connect a second battery; A switching device (100) according to any one of claims 2 to 12.

14. the at least one actuating element (117) comprises an electric motor configured to rotate the at least one driven member (124) of the transmission unit (116) to change the position of the movable busbar mechanism; and / or The switching device (100) according to any one of claims 2 to 13, wherein the force generated by the at least one actuating element (117) for changing the position of the movable busbar mechanism is transmitted by a worm gear (120, 122).

15. A power supply system including at least a first battery (500(1)), a second battery (500(2)), and a switching device (100) according to any one of claims 1 to 14, the first battery (500(1)) and the second battery (500(2)) are electrically connected to the switching device (100) so that the first battery (500(1)) and the second battery (500(2)) can be switched between a series state and a parallel state by the switching device (100); The series state is a state in which the first battery (500(1)) and the second battery (500(2)) are electrically connected in series by the switching device (100), and the parallel state is a state in which the first battery (500(1)) and the second battery (500(2)) are electrically connected in parallel by the switching device (100).

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