Safe charging module which is simple to install, charging system, and method for charging electric vehicles

Abstract

The invention relates to an electrical load comprising: a power input to be coupled to an additional electrical load, in particular an additional charging module for charging an electric vehicle, in particular precisely one electric car; and a first power output for transmitting power to yet another electrical load, in particular a charging module for charging an electric vehicle, in particular precisely one electric car; and a second power output for transmitting power to a power store, in particular a power store of an electric car; and a first data- and / or signal-line link for establishing a data- and / or signal-line link to the additional load; and a second data- and / or signal-line link for establishing a data- and / or signal-line link to the yet another load; wherein the first data- and / or signal-line link and the second data- and / or signal-line link comprise(s) or form(s) at least one part of a reset line for switching off the charging power and / or for restarting the load and preferably the additional load and particularly preferably the additional load, in particular the additional charging module, and the yet another load, in particular the additional charging module and the yet another charging module.

Description

[0001] Safe and easy-to-install charging module, charging system and method for charging electric vehicles

[0002] To ramp up electric mobility, a large number of charging stations are needed in private areas, for example, in employee parking spaces and underground garages in residential areas. The problem here is that neither the grid capacity nor the skilled workers are available to equip every parking space with a charging station.

[0003] The challenge of power grid capacity has already been solved with special charging stations that are built plug&play as a modular charging system in series as a decentralized energy system with built-in load management system, such as in 10 2017 124469.7.

[0004] The disadvantage here is that a large part of the installation cannot be performed by a layperson, as electrical safety regulations must be observed, and commissioning must be carried out by a qualified electrician, especially to ensure the functionality of the upstream safety equipment, especially the residual current device (RCD). Although the plug-and-play nature of a modular charging system makes installation faster and allows laypersons to assist with mechanical work such as plugging together the charging modules, a qualified electrician is still required for commissioning.

[0005] There are two main reasons for this:

[0006] 1) The current state of the art does not guarantee that all devices will always be de-energized during a plug-and-play extension. This is essential, as removing connectors under load damages them and can pose a long-term safety risk. Electrical engineers are aware of this, but laypeople are not. Often, laypeople don't have access to the backup fuse either.

[0007] 2) In addition, the safety technology "Fl" in the prior art is only pre-installed. Therefore, after each addition of a charging station or charging module to the chain, the function of the upstream residual current device (RCD) must be checked by a qualified electrician on each device. A wiring error or defective components could affect the upstream residual current device and render it inoperable. The aforementioned object is achieved according to the invention by an electrical consumer according to claim 1. The electrical consumer according to the invention, in particular a charging module for charging an electric vehicle, in particular precisely one electric car, preferably comprises at least:

[0008] A first data and / or signal line connection for generating a data and / or signal line connection with the further consumer and a second data and / or signal line connection for generating a data and / or signal line connection with the yet further consumer, wherein the first data and / or signal line connection and the second data and / or signal line connection have or form at least part of a reset line for switching off the charging current and / or for restarting the consumer and preferably the further consumer and particularly preferably the further consumer, in particular the further charging module, and the yet further consumer, in particular the further charging module and the yet further charging module.

[0009] Furthermore, the electrical consumer can have a current input for coupling to a further electrical consumer, in particular a further charging module for charging an electric vehicle, in particular precisely an electric car, and a first current output for forwarding current to a still further electrical consumer, in particular a charging module for charging an electric vehicle, in particular precisely an electric car, and a second current output for forwarding current to a power storage device, in particular a power storage device of an electric car.

[0010] This solution is advantageous because it allows the implementation of a modular charging system with an additional safety concept:

[0011] Further preferred embodiments are the subject of the following description parts and the subclaims: the consumer, in particular the charging module, has an assembly detection device, wherein the assembly detection device is connected to the reset line.

[0012] According to a further preferred embodiment of the present invention, the load is a battery storage device. According to a further preferred embodiment of the present invention, the installation detection device can trigger the shutdown of the charging current and / or the restart of the load via the reset line.

[0013] An installation detection device is primarily used to check whether the charging station is correctly installed. If this is the case, the power is released. The reverse test is also performed: If a charging station is removed from its installation location, all power outputs to electric vehicles and the power output of the first charging station, and thus all other charging stations in the system, are de-energized. "De-energized" in the following means that the connection to live conductors, in particular L1, L2, and L3, and the neutral conductor N, is severed.

[0014] According to a further preferred embodiment of the present invention, the assembly detection device comprises a sensor device for determining a correctly defined assembly situation of the consumer, in particular of the charging module, on a support structure, in particular a wall, and / or for determining a disassembly process.

[0015] According to a further preferred embodiment of the present invention, the switching off of the charging current and / or the restarting of the consumer can be triggered by the assembly detection device via the reset line as a function of sensor signals or sensor data of the sensor device.

[0016] According to a further preferred embodiment of the present invention, the sensor device has a permanent magnet and a Hall sensor, wherein the permanent magnet is formed or arranged on a wall mounting device of the consumer, in particular of the charging module, and the Hall sensor is formed or arranged on the remaining consumer, in particular a rear part of the consumer, in particular of the charging module, which can be coupled to the wall mounting device, or wherein the Hall sensor is formed or arranged on a wall mounting device of the consumer, in particular of the charging module, and the permanent magnet is formed or arranged on the remaining consumer, in particular a rear part of the consumer, in particular of the charging module, which can be coupled to the wall mounting device.

[0017] Fig. 1 shows, purely schematically and purely by way of example, a physical structure of a charging system according to the invention. The device according to the invention or the consumer according to the invention can preferably be a charging system or a charging module. The charging system is preferably constructed as a microgrid comprising several charging modules and preferably has a start module and a flexible number of extension modules (charging modules) (0 to n) which are or can be connected together in series via connecting cables. The first module of the device or of the charging system is always the start module; only this is directly connected to the power grid. Between the start module and the power grid is the pre-installation, which preferably has a fuse, at least one supply line to the start module and preferably also a circuit breaker and / or a residual current device.The start module preferably has a reset button for triggering a reset function, in particular of the start module and / or one or more extension modules.

[0018] The first extension module is preferably connected to the start module using plug&play via the connecting cable, the second extension module is particularly preferably connected to the first extension module using plug&play, and so on. Each module (start module / extension module(s) is preferably installed in its own parking space in order to provide a plug-in option or connection for an electric vehicle. Each charging module, regardless of whether it is a start module or extension module, is a connection option or charging point for an electric vehicle. Each charging module can be configured with either an attached cable or a Type 2 socket. Each charging module is characterized by the fact that it has a power input and preferably at least one, and particularly preferably two power outputs. One power output leads to another charging module, the other ends in a connection for an electric car. It is conceivable here, for example, that the last charging module orthe last expansion module has only one power input and one power output, in particular for charging an electric vehicle. The start module has a data and / or signal interface, in particular a data and / or signal input, for connections from outside, in particular from outside the microgrid. This external data connection can preferably be used to connect an OCPP backend. Each module preferably has a signal and / or data output to the next module. The expansion modules preferably each have a signal and / or data input from the previous module. A signal and / or data cable of the connecting cable preferably transmits the communication between the charging modules in the charging system or the device and particularly preferably contains one or more than one reset line for restarting the connected devices.The signal and / or data cables are preferably equipped at both ends with connectors, in particular plug-and-play connectors, for power and / or signals and / or data, preferably one connector for the power connection and one connector for all signal and / or data lines. Each charging module has a power, signal, and / or data connection to the electric vehicle connected or connectable to it.

[0019] Preferably, only one power connection on the start module is required for the entire charging system.

[0020] Each charging module includes, preferably in combination with its associated wall mounting plate, an installation detection device, a residual current detection device, and at least the start module, and preferably the extension modules, at least one associated shutdown device. Particularly preferably, the start module has two shutdown devices and the extension modules have one shutdown device.

[0021] Figure 2 shows a purely exemplary and schematic view of a consumer device, in particular a charging module with a mounting detection device. The housing of the charging station(s) is preferably designed for easy mounting on the associated wall mounting device, in particular a wall mounting plate.

[0022] The wall mounting device, in particular the wall mounting plate or

[0023] The wall mounting device preferably has jaws to provide protection against pulling out the power plugs and data and / or signal plugs. The power sockets and power plugs are preferably equipped with finger guards, meaning they prevent contact with the contacts.

[0024] According to a preferred embodiment of the present invention, for mounting on the wall, first a wall mounting device, in particular a wall mounting plate or

[0025] Wall mounting device. This allows the charging module to be easily attached and removed, while at the same time ensuring that the connectors are no longer accessible after the charging module has been mounted on the wall mounting device, especially the wall mounting plate, and providing the technical environment for installation detection.

[0026] A rear portion of the charging module, in particular a rear coupling device, in particular a rear shell, which is or can be connected to the wall mounting device, in particular the wall mounting plate, preferably forms the installation detection device or contains this, particularly preferably a sensor device, in particular one or more sensors for detecting whether the charging module is correctly installed. The sensor device can also be formed by the construction of a power and / or light and / or signal and / or data connection, in particular a light barrier and / or an RFID transmitting device with an associated RFID receiving device. Additionally or alternatively, the sensor device can comprise a distance measuring device for detecting a distance to a wall or a supporting structure to which the respective charging module is attached oris mounted, whereby the current can be provided as a result of a change in distance (assembly situation) or the current can be interrupted as a result of a change in distance (dismantling situation).

[0027] When reinstalling or connecting a charging module to the wall mount device, especially the wall mount plate, the installation detection function can be used to check whether the charging station is correctly installed and the connectors are no longer accessible. If the installation is recognized as completed correctly, the power is released.

[0028] Additionally or alternatively, it is possible that, for example, in the event of dismantling the charging station from the wall mounting device, preferably from the wall mounting plate, the output of the first charging station and thus all other charging stations in the system are switched off or can be switched off, in particular immediately when dismantling takes place or from the moment the sensor device detects a change in state or a signal or data which is output as a result of dismantling the charging station and the wall mounting device, in particular a relative movement of the charging station and the wall mounting device. In this way, the plug connectors exposed or accessible as a result of dismantling are switched off before they have even become accessible. In other words, they are preferably switched off before the dismantling process is completed or before the plug connectors can be reached manually.As a result, all accessible connectors in the system are preferably de-energized, thus fulfilling the requirement for installation by a layperson.

[0029] The installation detection can be realized either by the charging module alone or by the combination of charging module and wall mounting device, in particular wall mounting plate.

[0030] In the preferred embodiment, the combination of wall mounting device, in particular wall mounting plate, and charging module, in particular the rear shell of the charging module, is used to detect correct installation. The charging module contains the sensor device, in particular the sensor, the wall mounting device, in particular wall mounting plate, a defined geometric point or a defined object or property that is detected by the sensor in the charging module. However, it is also conceivable for the sensor device to be part of the wall mounting device, in particular wall mounting plate, and a defined geometric point or a defined object or property that is detected by the sensor device, in particular the sensor, in the wall mounting plate.

[0031] In the preferred embodiment, the detection that the charging module is mounted on the wall mounting device, in particular a wall mounting plate, is detected using a magnetic sensor, in particular a Hall sensor. For this purpose, a Hall sensor is preferably installed in the back shell of the charging module, which is connected, in particular soldered, to the charging module's electronics.

[0032] A permanent magnet is mounted in the wall mount, particularly the wall mount plate, specifically directly on the underside of the Hall sensor. When the charging module is removed from the wall mount, particularly the wall mount plate, the absence of a magnetic field triggers the Hall sensor (high voltage), which sets the reset line to low (low voltage), particularly via a transistor.

[0033] All charging modules in the system are connected via the reset line. If this line is low, all charging modules are restarted or "reset," opening their charging current switches. Preferably, one of the shutdown devices, preferably contactors or relays, is deactivated for the charging current, thus aborting their charging processes and de-energizing their individual charging plugs. This is preferably achieved via the charging controller ("SCO") in each charging module. The SCO actively switches the charging current switch. Normally, without a signal from the SCO, the charging current switch is "open," and the charging current plug is de-energized. During the charging process, the SCC releases the charging process to the electric vehicle by closing the charging current switch, thus connecting the charging plug to the power bus. If the SCC is restarted via the reset line, the charging current switch is automatically opened and the charging plug is de-energized.

[0034] Additionally or alternatively, according to a further preferred embodiment of the present invention, by setting the reset line to low (voltage “Low”), a power-cut switch device, in particular a power-cut switch, ie one of the shutdown devices, in the start module can be opened, whereby the output of the start module is switched off and thus all other charging modules in the series are also de-energized.

[0035] The test is preferably permanently activated and, more preferably, purely signal- and / or data-controlled. If an attempt is made to reconnect the power when a charging module is incorrectly installed, it is immediately detected if a charging module is not connected to its wall mounting device, especially the wall mounting plate. The power is immediately disconnected.

[0036] This resets all charging modules or modules in the system or in the load chain if one of the charging modules or modules is not installed. All charging modules or modules that are currently charging are deactivated. All connectors in the system or in the load chain downstream of the start module's input are de-energized.

[0037] Additional or alternative implementations of assembly detection could include using a tilt sensor to detect whether the module is tilted by, for example, more than 30 degrees, thus invalidating a vertical position. This implementation would be more cost-effective; the main disadvantage of this approach is that the system would temporarily detect correct assembly if the module were held in a vertical position after disassembly. This could be solved with an additional accelerometer and gyro sensor to detect that the module is truly firmly mounted. This combination would then be very complex and no longer cost-effective.

[0038] Other embodiments would be IR, ultrasonic and optical sensors: The implementation of these sensors for dismantling detection requires a transmitter and a receiver, which leads to a lot of complexity in the wall mount plate.

[0039] Another design would be a distance sensor that measures a precisely defined distance between the wall mount plate and the charging module to detect correct installation. This would also only add complexity to the charging module, but the components are very expensive.

[0040] Fig. 3 shows schematically and purely as an example a residual current detection with coupled switching device(s).

[0041] According to a further preferred embodiment of the present invention, the consumer, in particular the charging module, has a fault current detection device, wherein the fault current detection device is connected to the reset line.

[0042] This embodiment is advantageous because a system of residual current detection devices (“ROD”) in each module or charging module and corresponding disconnection devices coupled thereto, both in and between the modules, protects every exposed contact, in particular plug connections from plugs and sockets, and every line in the system.

[0043] According to a further preferred embodiment of the present invention, the fault current detection device is configured to carry out a self-test, wherein the fault current detection device is configured to trigger the switching off of the charging current and / or the restarting of the consumer via the reset line depending on a result of the self-test.

[0044] Conventional charging stations have only one input from the power grid and one output to the electric car. The charging system presented here, like a plug-and-play charging system, can be set up in series as a decentralized energy system with a built-in load management system, as in DE 102017 124469.7, and also has a power output to the next charging module.

[0045] Additionally, the state-of-the-art "FI" safety technology, both in a regular charging station and in a modular charging system with in-line installation, is only pre-installed. Therefore, after adding a new charging module to the chain, the function of the upstream residual current device (RCD) must be checked by a qualified electrician on each device. A wiring error or defective components could affect the upstream residual current device and render it inoperable.

[0046] In order to avoid repeated testing of the upstream residual current device, a residual current detection device (“ROM”) and preferably two connected shutdown mechanisms, one in the respective charging module and one preferably globally in the starting module, are preferably integrated in each charging module.

[0047] The residual current detection device n is preferably connected downstream, especially directly downstream, of the power socket of the respective charging module. "Downstream" here means further away from the power grid in the current flow. This allows for the detection of leakage currents both at the power output and thus in the power cable connection of the power bus, as well as at the power output to the electric vehicle.

[0048] According to a further preferred embodiment of the present invention, the residual current detection devices are particularly preferably designed so that they can test themselves for functionality, preferably according to the specifications of the RCD self-test of the IEC62752 standard for mobile chargers.

[0049] A system of residual current detection devices in each module or charging module and corresponding disconnection devices connected to them, within and / or between the modules or charging modules, preferably protects every exposed contact and / or, more preferably, every line in the system or consumer chain. The charging current via the charging connector to the electric vehicle and / or the power line to the next module or charging module is preferably protected in this way.

[0050] According to a further preferred embodiment, the combination of the fault current detection and shutdown mechanisms is designed to meet the tripping characteristics of the IEC62752 standard for mobile chargers and to trip after 20 / 30 mA AC and 6 mA DC.

[0051] A residual current device (RCD) is an electrical safety device that quickly interrupts a circuit with leakage current to earth. It serves to protect devices, especially charging modules, and reduce the risk of serious damage from sustained electric shock. The above-mentioned object can be achieved according to the invention by a method for operating a charging module or a system comprising multiple charging modules. According to the method, the charging module(s) of the system are equipped with a residual current detection device, and the charging module(s) of the system test the functionality of the residual current detection device by means of a self-test.

[0052] According to a further preferred embodiment of the present invention, an error is signaled to the user via a red LED and / or a smartphone app if the self-test fails. A self-test is considered successful if the residual current detection device is functioning or functioning correctly.

[0053] According to a further preferred embodiment of the present invention, the individual charging module or module or preferably the entire charging system, in particular all charging modules, i.e. all charging modules in the series, is switched to inactive if the self-test was not successful.

[0054] If the test is positive and the fault current detection is working, a charging process can be started, in particular on the charging module or on the respective charging module or on all charging modules.

[0055] According to a further preferred embodiment of the present invention, the at least one but preferably two shutdown mechanisms are activated when a fault current is detected at the charging module during operation, in particular by means of the fault current detection device.

[0056] According to a further preferred embodiment of the present invention, the charging module, whose fault current detection device has detected the fault current, opens its charging current switch via a coupling in order to de-energize the charging plug.

[0057] According to a further preferred embodiment of the present invention, the respective charging module preferably additionally activates the reset by setting the reset line to the low level (voltage "low"). This is advantageous because it also stops all charging processes in all charging modules and activates the power-cut switch in the start module, which de-energizes the power output of the start module and thus disconnects all subsequent charging modules from power. Additionally, an error in the charging module can be indicated or output to the user and operator, preferably via the smartphone app and / or the LED on the charging module, preferably in red.

[0058] According to a further preferred embodiment of the present invention, after tripping due to fault currents, reactivation must not be possible without user intervention. Particularly preferably, user interaction must initiate a self-test before charging.

[0059] The charging system is therefore preferably inactive until a user performs a restart and thus initiates a new self-test of the charging system and the residual current functionality.

[0060] According to a further preferred embodiment of the present invention, the charging system can be restarted either via the cloud app and / or the reset button, preferably on the start module, or switched on and off at the pre-installation by operating the residual current circuit breaker or circuit breaker.

[0061] According to a further preferred embodiment of the present invention, each charging module performs an automated self-test of the residual current detection device during operation, in particular to check the system's ability to detect residual currents. This is preferably performed periodically at defined time intervals, in particular every 10 minutes, and / or preferably always before starting the charging process. The test preferably lasts at least 500 ms. If the test is negative, the charging module is deactivated, all charging processes are stopped, and a charging module error is indicated to the user and operator, preferably via the smartphone app and the LED on the charging module, preferably in red.

[0062] According to another preferred embodiment of the present invention, the start module detects that the reset line has been pulled to "low." The reset line can be pulled to low, for example, if a negative assembly detection occurs or a fault current is detected.

[0063] According to a further preferred embodiment of the present invention, the start module always monitors the reset line, regardless of the cause. This is advantageous because it causes the start module to actively set the reset line to a low level (voltage "LOW") until the user restarts. This prevents the power supply to the charging modules from being restored.

[0064] To distinguish whether the reset line was pulled low by the installation detection device or the residual current detection device, thus triggering the reset, the start module can read a residual current detection value from its own residual current detection device. Since all residual current detection devices in the chain trigger simultaneously when a residual current occurs, it can be verified, for example, that the reset was triggered by a residual current. This information is then transmitted to a backend system, preferably an OCPP backend.

[0065] The charging modules preferably communicate the results of their residual current tests and self-tests periodically to the start module, which then sends them outwards, preferably via the data connection, preferably via the backend to the user or operator.

[0066] The present invention can thus relate to an electrical consumer, in particular a charging module for charging an electric vehicle, in particular precisely an electric car, wherein the electrical consumer has at least: a current input for coupling to a further electrical consumer, in particular a further charging module for charging an electric vehicle, in particular precisely an electric car, or a power source, in particular a power bus, and a first current output for forwarding power to a yet further electrical consumer, in particular a charging module for charging an electric vehicle, in particular precisely an electric car, and a second current output for forwarding power to a power storage device, in particular a power storage device of an electric car,and a first data and / or signal line connection for generating a data and / or signal line connection with the further consumer or the power source and a second data and / or signal line connection for generating a data and / or signal line connection with the yet further consumer, wherein the first data and / or signal line connection and the second data and / or signal line connection comprise or form at least part of a reset line for switching off the charging current and / or for restarting the consumer and preferably the further consumer or the power source and particularly preferably the further consumer, in particular the further charging module, or the power source and the yet further consumer, in particular the further charging module and the yet further charging module.

Claims

Claims 1. Electrical consumer, in particular a charging module for charging an electric vehicle, in particular exactly one electric car, comprising at least one power input for coupling to another electrical consumer, in particular a further charging module for charging an electric vehicle, in particular exactly one electric car, or a power source, in particular a power bus, and a first power output for forwarding power to a yet further electrical consumer, in particular a charging module for charging an electric vehicle, in particular exactly one electric car, and a second power output for forwarding power to a power storage device, in particular a power storage device of an electric car,and a first data and / or signal line connection for generating a data and / or signal line connection with the further consumer or the power source and a second data and / or signal line connection for generating a data and / or signal line connection with the yet further consumer, wherein the first data and / or signal line connection and the second data and / or signal line connection comprise or form at least part of a reset line for switching off the charging current and / or for restarting the consumer, and preferably the further consumer or the power source, and particularly preferably the further consumer, in particular the further charging module, or the power source and the yet further consumer, in particular the further charging module and the yet further charging module. 2 Electrical consumer according to claim 1, characterized in that the consumer, in particular the charging module, has an assembly detection device, wherein the assembly detection device is connected to the reset line. 3 Electrical consumer according to claim 2, characterized in that the switching off of the charging current and / or the restarting of the consumer can be triggered by the assembly detection device via the reset line. Electrical consumer according to claim 3, characterized in that the installation detection device has a sensor device for determining a correctly defined installation situation of the consumer, in particular the charging module, on a support structure, in particular a wall, and / or for determining a disassembly process. Electrical consumer according to claim 4, characterized in that the installation detection device can trigger the switching off of the charging current and / or the restarting of the consumer via the reset line depending on sensor signals or sensor data from the sensor device.Electrical consumer according to claim 4 or 5, characterized in that the sensor device has a permanent magnet and a Hall sensor, wherein the permanent magnet is formed or arranged on a wall mounting device of the consumer, in particular of the charging module, and the Hall sensor is formed or arranged on the remaining consumer, in particular a rear part of the consumer, in particular of the charging module, which can be coupled to the wall mounting device, or wherein the Hall sensor is formed or arranged on a wall mounting device of the consumer, in particular of the charging module, and the permanent magnet is formed or arranged on the remaining consumer, in particular a rear part of the consumer, in particular of the charging module, which can be coupled to the wall mounting device.Electrical consumer according to one of the preceding claims, characterized in that the consumer, in particular the charging module, has a fault current detection device, wherein the fault current detection device is connected to the reset line. Electrical consumer according to claim 7. characterized in that the fault current detection device is configured to perform a self-test, wherein the fault current detection device is configured to trigger the switching off of the charging current and / or the restarting of the consumer via the reset line depending on a result of the self-test. Charging system comprising a start module and at least one charging module according to one of the preceding claims connected to the start module via a data and / or signal line connection. Method for charging, in particular time-delayed charging, electric vehicles comprising a charging system according to claim 9, wherein the step of determining a fault current detection and / or the step of determining an assembly detection is carried out.

Images