Electronic module and charging system

Abstract

The electronic module is configured for charging an electric vehicle. The electronic module comprises a charge controller unit, a safety unit and an energy monitoring unit. The charge controller unit, the safety unit and the energy monitoring unit are arranged in a common housing. The charge controller unit and the safety unit are further arranged directly in a charging path for the electric vehicle.

Description

[0001] Description

[0002] ELECTRONIC MODULE AND CHARGING SYSTEM

[0003] An electronic module , in particular for charging an electric vehicle , and a charging system are speci fied .

[0004] One obj ect to be achieved is , inter alia, to speci fy an improved electronic module that has a particularly small si ze . A further obj ect to be achieved is , inter alia, to provide a charging system comprising such an electronic module .

[0005] These obj ects are achieved by an electronic module comprising the features of independent claim 1 and by a charging system comprising the features of claim 10 , respectively . Advantageous embodiments and further developments are the subj ect-matter of the respective dependent patent claims .

[0006] In at least one embodiment , the electronic module is configured for charging an electric vehicle . The electronic module comprises a charge controller unit , a safety unit and an energy monitoring unit . The charge controller unit , the safety unit and the energy monitoring unit are arranged in a common housing . The charge controller unit and the safety unit are further arranged directly in a charging path for the electric vehicle .

[0007] In particular, the electronic module controls and preferably monitors a charging process of the electric vehicle . For this purpose the electronic module is directly arranged in a charging path for the electric vehicle . In particular, the charging path electrically connects the electric vehicle with an electric grid, for example of a private home , such as a household grid .

[0008] The electronic module is based on the following technical considerations . Common charge controllers for electric vehicles are typically not arranged directly in the charging path . Furthermore , commonly additional external components are necessary such as a DC residual current detection . This requires additional sensors , for example , to detect the residual current . However, wiring for these additional sensors and the charging path have to be carefully separated from each other, in order to ful fil safety standards .

[0009] Furthermore , the additional external components are typically arranged in a so-called wall-box, which consumes space , for example at a parking location for the electric vehicle such as a garage .

[0010] The electronic module makes use of the idea to integrate a safety unit such as a DC residual current circuit breaker comprising preferably a DC residual current detection and a charge controller for an electric vehicle in a common housing . Furthermore , the electronic module is directly integrated in a charging path of the electric vehicle . This allows for a space-saving charging system . At the same time installation complexity is reduced .

[0011] Furthermore , additional sensors that monitor a DC residual current are not necessary and can be omitted . Therefore , a smaller si ze for the electronic module can be achieved . In addition, a wall-box is not needed . Furthermore , safety is increased since no additional wiring connecting of an external sensor is required . Preferably, the housing in which the charge controller unit and the safety unit are arranged is a rail housing, in particular a DIN rail housing . Such a rail housing allows for a panel integration, for example in a distribution board of a private home . Advantageously, the electronic module can therefore be easily installed and maintained, while a space consumption of the electronic module can be kept comparably small .

[0012] It is possible that the electronic module further comprises a communication unit . Preferably, the communication unit is arranged in the housing . By arranging the communication unit in the housing, the space consumption of the electronic module can be kept low .

[0013] The communication unit preferably allows for an external communication to an electric device . Thereby, for example , a charging process of the electronic vehicle can be monitored . Additionally or alternatively, the charging process may be externally controlled . In particular, the charging process may be externally activated and / or parameters of the charging process may be determined . For example , a user may observe the progress of the charging process of the electric vehicle and / or may turn on or of f the charging process .

[0014] For example , the communication unit is an RF-module . Preferably, the communication unit is configured to communicate wirelessly . By using an RF-module , particular for a wireless communication, the user may observe the charging process or take action with respect to the charging process on a mobile device such as a mobile phone or a tablet computer . Alternatively, it is possible that the communication unit may be connected to a display or a control panel or the like by a wired connection .

[0015] Furthermore , the electronic module may communicate with a central maintenance service or the like . Thereby, a system status of the electronic module may be transmitted to an external server of the central maintenance service . The central maintenance service may monitor a plurality of electronic modules in order to observe mal functions or perturbations of a plurality of electronic modules .

[0016] It is also possible that the electronic module may communicate with di f ferent electric devices of a household grid the electronic module is integrated in . For example , the electronic module may be part of so-called smart home grid . This allows the controlling of the electronic module and hence the charging process of the electric vehicle from a central controlling device of the smart home grid .

[0017] The electronic module further comprises an energy monitoring unit integrated in the common housing . By the energy monitoring unit , a power consumption of the charging system and / or a charging level of the electric vehicle , may be determined and / or observed . In particular, a charging current and additionally a charging voltage are measured by the energy monitoring unit to determine and optionally visuali ze the power consumption . The power consumption measured by the energy monitoring unit is , for example , visuali zed and communicated by the communication module . The safety unit may comprise a DC residual current detection unit . The safety unit , or, more speci fically the DC residual current detection unit , is preferably configured for detection of a residual current , in particular a DC residual current , of 6 mA. In particular, i f in intended operation a residual current of 6 mA or more is detected, the residual current detection unit breaks an electrical connection of the electronic module to the electric vehicle . For this purpose , the safety unit , or the DC residual current detection unit , comprises a DC residual current circuit breaker .

[0018] With such a safety unit safety standards for charging electric vehicles can be met . In common charging systems , such a DC residual current detection unit is typically a distinct element that is arranged in a distinct external housing, for example a wall-box . By integrating said DC residual current detection unit in the common housing together with the charge controller, such an external wallbox may become obsolete and can be omitted . This advantageously reduces the si ze of the electronic module .

[0019] The safety unit may further comprise a miniature circuit breaker, an AC residual current circuit breaker, and / or a contactor . Preferably at least one or all of these elements may be integrated in the housing, advantageously allowing for si ze reduction . In particular, at least one or all of these elements may be part of the safety unit .

[0020] The electronic module may further comprise a first connector configured to connect to a low-voltage grid . The low-voltage grid may be a private home grid or a household grid . The first connector may comprise a plurality of contacts to connect to the low-voltage grid . Each of the contacts may be formed as a terminal comprising, for example , a terminal screw .

[0021] The electronic module may further comprise a second connector and a third connector configured to connect to a contactor and / or a relay . The contactor or the relay may be an external , distinct device or may be integrated in the housing . Each of the second connector and third may comprise a plurality of contacts to connect to the contactor . Each of the contacts may be formed as a terminal comprising, for example , a terminal screw .

[0022] For example , via the second connector a power path comprising three phases and a neutral line between the electronic module and the contactor may be established . Via the third connector the electronic module may be connected to and / or control a coil of the contactor .

[0023] In particular, the second connector is configured to electrically connect phases and a neutral line of the low- voltage grid, which are for example received by the electronic module via the first connector, to the electric vehicle over the contactor .

[0024] The electronic module may further comprise a fourth connector configured to connect to a cable electrically connecting the electronic module to the electric vehicle . The fourth connector may comprise a plurality of contacts to connect to the electronic vehicle . Each of the contacts may be formed as a terminal comprising, for example , a terminal screw . For example , by the fourth connector a control signal may be transmitted to the electronic vehicle . That is , the fourth connector may be , for example , configured for controlling the charging process .

[0025] For example , the charging path is formed by the low-voltage grid, connected to the electronic module via the first connectors , the electronic module , and the cable connected to the electronic module via the second connector over the contactor . Hence , the electronic module is arranged directly in the charging path .

[0026] Furthermore , a charging system, in particular for an electric vehicle , is speci fied . In particular, the charging system comprises an electronic module described herein . This means that all features disclosed for the electronic module are also disclosed for the charging system and vice versa .

[0027] The charging system comprises a circuit protection device and a contactor . The electronic module is electrically arranged between the circuit protection device and the contactor . The circuit protection device may comprise an AC residual current circuit breaker and / or a miniature circuit breaker .

[0028] Preferably, the circuit protection device and / or the contactor are arranged in a DIN rail housing . Hence , the charging system may be arranged together on a panel . In particular, the charging system can be arranged in a distribution board of a household grid .

[0029] It is possible that the contactor is arranged in the housing of the electronic module . Additionally or alternatively, it is possible that the circuit protection device is arranged in the housing of the electronic module . This means that the charging system may completely be integrated into the housing . This advantageously allows a reduction of the space occupied by the charging system . Furthermore , installation and maintenance of the charging system can be facilitated .

[0030] The charging system may further comprise a cable configured to connect the electric vehicle to the electronic module .

[0031] Further advantages and advantageous embodiments and further developments of the electronic module and the charging system described herein will become apparent from the following exemplary embodiments shown in connection with schematic drawings . Identical elements , elements of the same kind or elements having the same ef fect , are provided with the same reference signs in the figures . The figures and the proportions of the elements shown in the figures are not to be regarded as true to scale . Rather, individual elements may be shown exageratedly large for better representability and / or for better comprehensibility .

[0032] In the figures :

[0033] Figure 1 shows a schematic perspective view of an electronic module described herein according to an exemplary embodiment ;

[0034] Figure 2 shows a schematic block diagram illustrating the components of the electronic module according to the exemplary embodiment ; and

[0035] Figure 3 shows a schematic perspective view of a charging system described herein according to an exemplary embodiment .

[0036] The electronic module 1 according to the exemplary embodiments shown in Figures 1 and 2 comprises a charge controller unit 2 , a safety unit 3 , a communication unit 4 , an energy monitoring unit 5 , a power supply 9 , a first connector 11 , a second connector 12 and a third connector 13 , arranged in a common housing 10 . The housing 10 is a DIN rail housing .

[0037] The electronic module 1 is configured for controlling a charging process of an electric vehicle . Since the electronic module 1 comprises the charge controller 2 configured to control and monitor the charging process and the safety unit 3 , which comprises a DC residual current detection and a corresponding circuit breaker, the electronic module 1 may be installed directly in a charging path of the electric vehicle . The charging path in particular connects the electric vehicle with an electrical grid, such as a household grid . The safety unit is configured for detection of a residual current of 6 mA.

[0038] Advantageously this allows for omitting additional external sensors for DC residual current detection . Furthermore , installation and maintenance of the electronic module is easier compared to common charging systems , where the DC residual current detection and the charge controller are distinct entities . In addition, space consumption of the electronic module 1 is smaller compared to common charging systems , where the DC residual current detection is typically arranged in a so-called wall-box, which consumes space at a parking location of the electric vehicle .

[0039] The communication module 4 is configured as an interface for external communication . For example , by the communication module 4 a wireless communication to a mobile device is possible . The communication module 4 preferably comprises an RF-module . The housing 10 comprises a communication module

[0040] LED 16 , indicating an activity of the RF-module .

[0041] By the communication module 4 , parameters of the charging process may be set by a user . Furthermore , the user may monitor the status of the charging process or start the charging process .

[0042] The energy monitoring unit 5 is configured to determine a power consumption of the charging process . To achieve this , the energy monitoring unit 5 measures a charging current and a charging voltage and calculates the power consumption . The resulting power consumption, the charging current and / or the charging voltage may be communicated by the communication module 4 .

[0043] The first connector 11 is configured to connect to a low- voltage grid . The low-voltage grid is , for example , a household grid . The first connector 11 comprises a first contact 111 , a second contact 112 , a third contact 113 and a fourth contact 114 . Each of the first to third contacts 111 to 113 is configured to electrically connect to a phase of the low-voltage grid . The fourth contact 114 is a neutral contact . Each of the first to fourth contacts 111 to 114 is formed by terminal screws , for example .

[0044] The second connector 12 is configured to connect to a contactor 6 . In the present embodiment , the contactor 6 is arranged as a distinct element outside the housing 10 . In an alternative embodiment , the contactor 6 may be arranged inside the housing 10 . In this case , the second connector 12 may be omitted . The second connector 12 comprises a first contact 121 , a second contact 122 , a third contact 123 and a fourth contact 124 . Each of the first to fourth contacts 121 to 124 comprises a terminal . The first to fourth contacts 121 to 124 may be arranged on an underside of the housing 10 .

[0045] Each of the first to third contacts 121 to 123 is configured to electrically connect a phase of the low-voltage grid to the electric vehicle over the external contactor . In particular, this connection forms a power path to the electronic vehicle . The fourth contact 124 is a neutral contact .

[0046] The third connector 13 comprises a first and a second contact 131 , 132 formed as terminals . The third connector is configured to contact to a control coil of the contactor 6 . The first and second contacts 131 , 132 may be arranged on an underside of the housing 10 .

[0047] The fourth connector 14 is configured to connect to a cable 8 which is electrically conductively connected to the electric vehicle . The fourth connector 14 comprises a first contact 141 and a second contact 142 Each of the first and second contacts 141 and 142 comprises a terminal screw . In particular by the fourth connector 14 a control path to the electronic vehicle is established .

[0048] The electronic module 1 further comprises a power LED 15 . The power LED 15 indicates in intended operation that the electronic module 1 is activated . The electronic module 1 further comprises a charging LED 17 .

[0049] The charging LED 17 indicates in intended operation that a charging process is in progress .

[0050] Figure 3 illustrates a charging system 100 according to an exemplary embodiment . The charging system 100 includes an electronic module 1 . The electronic module 1 is in particular the electronic module 1 according to the exemplary embodiment shown in Figures 1 and 2 .

[0051] The charging system 100 further comprises a contactor 6 . In an alternative embodiment , the charging system 100 may additionally or alternatively comprise a relay .

[0052] The charging system 100 further comprises a circuit protection device 7 such as an AC residual current circuit breaker . The circuit protection device 7 may comprise a miniature circuit breaker .

[0053] The contactor 6 and the circuit protection device 7 are arranged in a DIN rail housing . This means that the electronic module 1 can be arranged together with the contactor 6 and circuit protection device 7 in a particularly space-saving manner, for example in an electric distribution board of a household .

[0054] In alternative embodiments the circuit protection device 7 and / or the contactor 6 and / or the relay may be arranged in the housing 10 of the electronic module 1 . This reduces further the space occupied by the charging system 100 . In this case , the circuit protection device 7 may be part of the safety unit 3 of the electronic module 1 . In particular, an input 71 of the circuit protection device 7 is connected to the low-voltage grid . An output 72 of the circuit protection device 7 is connected to an input of the electronic module 1 , preferably formed by the first connector 11 . This connection is preferably a power connection with three phases and a neutral line . An output of the electronic module , for example formed by the second connector 12 , is electrically connected to an input 61 of the contactor 6 . Preferably, this connection is a power connection with three phases and a neutral line . Furthermore , the third connector 13 of the electronic module 1 is electrically connected to a coil input port 63 of the contactor 6 in order to contact a control coil of the contactor 6 . An output 62 of the contactor 6 as well as the fourth connector 14 of the electronic module may be connected to the electronic vehicle via a cable 8 . In particular, the lines of the cable 8 connected to the contactor 6 form a power path to the electronic vehicle . The lines of the cable 8 connected to the fourth connector 14 form a control path to the electronic vehicle .

[0055] That is , a charging path of the electronic vehicle that connects the electronic vehicle with the low-voltage grid proceeds from the low-voltage grid over the input 71 of the circuit protection device 7 , the output 72 of the circuit protection device 7 , the first connector 11 of the electronic module 1 , the second connector 12 of the electronic module 1 , the input 61 of the contactor 6 , the output of the contactor 62 to the cable 8 . Additionally, a charging process may be controlled by the electronic module 1 over the fourth connector 14 , connecting to the electric vehicle via the cable 8 . The invention is not restricted to the exemplary embodiments by the description on the basis of said exemplary embodiments . Rather, the invention encompasses any new feature and also any combination of features , which in particular comprises any combination of features in the patent claims and any combination of features in the exemplary embodiments , even i f this feature or this combination itsel f is not explicitly speci fied in the patent claims or exemplary embodiments .

[0056] References electronic module

[0057] 2 charge controller unit

[0058] 3 safety unit

[0059] 4 communication unit

[0060] 5 energy monitoring unit

[0061] 6 contactor

[0062] 7 circuit protection device

[0063] 8 cable

[0064] 9 power supply

[0065] 10 housing

[0066] 11 first connector

[0067] 16 communication module LED

[0068] 17 charging LED

[0069] 61 input of the contactor

[0070] 62 output of the contactor

[0071] 63 coil input port

[0072] 71 input of the circuit protection device

[0073] 72 output of the circuit protection device

[0074] 100 charging system

[0075] 111...114 first to fourth contact of first connector

[0076] 121...124 first to fourth contact of second connector

[0077] 131 , 132 first and second contact of third connector

[0078] 141 , 142 first and second contact of the fourth connector

Claims

Claims1. An electronic module (1) for charging an electric vehicle, the electronic module comprising a charge controller unit (2) , a safety unit (3) and an energy monitoring unit (5) , wherein the charge controller unit (2) , the safety unit (3) and the energy monitoring unit (5) are arranged in a common housing (10) , and wherein the charge controller unit (2) and the safety unit (3) are arranged directly in a charging path for the electric vehicle.

2. The electronic module (1) according to claim 1, wherein the housing (10) is a rail housing.

3. The electronic module (1) according to claim 1 or 2, further comprising a communication unit (4) arranged in the housing (10) .

4. The electronic module (1) according to claim 3, wherein the communication unit (4) is an RF module.

5. The electronic module (1) according to claim 3 or 4, wherein the communication unit (4) is configured to communicate wirelessly.

6. The electronic module (1) according to one of the preceding claims, wherein the safety unit (3) comprises a DC residual current detection unit and is configured for detection of a residual current of 6 mA.

7. The electronic module (1) according to one of the preceding claims, further comprising a first connector(11) configured to connect to a low-voltage grid.

8. The electronic module (1) according to one of the preceding claims, further comprising a second connector(12) and a third connector (13) configured to connect to a contactor ( 6 ) .

9. The electronic module (1) according to one of the preceding claims, further comprising a fourth connector(14) configured to connect to a cable (8) electrically connecting the electronic module (1) to the electric vehicle .

10. A charging system (100) for an electric vehicle, the charging system comprising- an electronic module (1) according to one of the preceding claims,- circuit protection device (7) , and- a contactor ( 6 ) , wherein the electronic module (1) is electrically arranged between the circuit protection device (7) and the contactor (6) .

11. The charging system (100) according to claim 10, wherein the contactor (6) is arranged in the housing (10) of the electronic module (1) .

12. The charging system (100) according to claim 10 or 11, further comprising a cable (8) configured to connect the electronic vehicle to the electronic module (1) .

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