Charging station for electric vehicles, in particular commercial vehicles, and retrofittable coupling unit for charging stations

Abstract

The invention relates to a charging station for electric vehicles, comprising: a converter, a charging cable (20, 24) for establishing an electrical connection between the converter and an electric vehicle to be charged, an adapter unit (22), a linear receptacle (38) arranged remote from the ground, and a linear guide (66, 68), wherein the charging cable (20, 24) has a first charging cable section (20) and a second charging cable section (24) which are connected to one another via the adapter unit (22), wherein the linear receptacle (38) is designed to receive the second charging cable section (24) when not in use, and wherein the linear receptacle (38) and the adapter unit (22) are arranged on the linear guide (66, 68) so as to be displaceable.

Description

[0001] Charging station for electric vehicles, especially commercial vehicles, and retrofittable coupling unit for charging stations

[0002] TECHNICAL FIELD OF THE INVENTION

[0003] The invention relates to a charging station for the efficient and low-loss charging of electric vehicles, in particular commercial vehicles. The invention also relates to a retrofittable coupling unit for such charging stations.

[0004] BACKGROUND OF THE INVENTION

[0005] The term "electric vehicles" is generally understood to mean vehicles with rechargeable batteries that are to be charged by external sources, regardless of whether they are vehicles that are only electrically powered or so-called hybrid vehicles that use combustion or other engines in addition to one or more electric motors.

[0006] The fast and at the same time energy-efficient charging of electric vehicles is a non-trivial problem due to the associated current intensities, especially when the electric vehicles are commercial vehicles such as buses, tractors, trucks, agricultural machinery, rail vehicles, etc., which have a high power consumption due to their own weight and require correspondingly large batteries.

[0007] While private vehicles often only travel a certain distance, such as to work, and then stand still for an extended period during which they can be charged without time pressure, rapid charging is essential in the commercial vehicle sector. For buses used in public transport, for example, the goal is a charging time of less than three minutes for a partial charge, sufficient for a range of 100 kilometers.

[0008] Corresponding charging stations are to be designed for power outputs in the range of several hundred kilowatts up to about one megawatt.

[0009] Fast charging, however, requires high currents ranging from several hundred to several thousand amperes to be carried through appropriate charging cables. While high-temperature superconducting cables can conduct such currents without loss, they still require cooling to minus 196°C and are only suitable for stationary installation, but not for manually connecting to an electric vehicle as a charging cable.

[0010] Conventional power cables, especially copper cables, can also conduct the aforementioned currents with low losses. However, this requires the wires within the cables to have large cross-sections, making them not only heavy but also very stiff, and therefore unsuitable for manually connecting them to the vehicle being charged. Lighter cables with smaller cross-sections heat up quickly and thus result in very high conduction losses.

[0011] To avoid the problems associated with wired charging stations, inductive charging has also been proposed. WO 2018 / 171658 A1, for example, proposes integrating induction coils into the roofs of electric vehicles, allowing the electrical connection for charging to be established via appropriate devices in a garage or carport roof. This advantageously eliminates the need for handling charging cables and keeps the available routes free of "gas pumps" and cables. However, this approach does not achieve the charging power required for rapidly charging large-sized batteries. To prevent overheating of the transmitting and receiving coils at the power levels in question, they would require complex cooling. Furthermore, at transmission power levels in the kilowatt or even megawatt range, damage to people, animals, and electronic devices in the vicinity of a transmitting coil would be unavoidable.In addition, the transmitting and receiving coils must be positioned as close to each other as possible for efficient transmission of electrical energy, which requires complex mechanisms for adjusting the transmitting coils in vehicles with different heights and different roof contours.

[0012] An improved wired charging station is proposed in DE 202017 101 551 U1. It uses a fluid-cooled charging cable, which, when in use, is connected not only to a converter (also called a charging rectifier) ​​to provide the charging current, but also to a pump for circulating a fluid coolant through the cable. The pump and a heat exchanger used to cool the coolant are arranged in a type of gas pump, which also contains a converter that rectifies the supplied three-phase current and generates a direct current suitable for the respective batteries to be charged. The typical design of such a gas pump-like charging station is described in DE 20 2018 103 809 U1.

[0013] However, the pump-like design of a charging station presents a host of problems when multiple vehicles are to be charged simultaneously, for example, in a depot or large parking lot. The pumps require additional dedicated parking space and restrict the freedom of movement of personnel and vehicles. Furthermore, the pumps must be specially insulated and fire-protected, as they house converters for transforming what can be high-voltage three-phase current and can therefore become very hot during operation. Simply positioning the pumps away from the vehicles and equipping them with long charging cables is not a solution, as the use of long, cooled cables completely defeats the goal of environmentally friendly driving due to the heat losses that occur in these cables and the energy required to cool them.

[0014] DE 102022 123 919 A1 presents a charging station and a charging method that solve the problems associated with pump-type charging stations and not only enable particularly efficient and low-loss charging of electric vehicles, especially commercial vehicles, but are also suitable for charging vehicles of different heights without significantly impairing the stationary parking and maneuvering space available for the vehicles.

[0015] To this end, DE 102022 123 919 A1 proposes dividing the charging cable into two sections connected via an adapter unit to establish an electrical connection between a converter and an electric vehicle to be charged. These sections are connected via an adapter unit, namely a first, uncooled charging cable section between the converter and the adapter unit, and a second, cooled charging cable section between the adapter unit and the vehicle to be charged. This advantageously allows the use of cables with a large cross-section in the first charging cable section, which can be installed stationary, for the lowest possible loss in conducting high currents, for example, in the range of several hundred to several thousand amperes, so that this charging cable section is correspondingly heavy.In contrast, the second charging cable section, which should be as light as possible to make it easy to handle, can be kept relatively short, which offers several advantages: Since the second charging cable section is intended to be lightweight, the cross-sections of the electrical cables it contains are smaller than the cross-sections of the cables in the first charging cable section, which means that the second charging cable section heats up and leads to line losses. To compensate for this heating, the second charging cable section is cooled, which also consumes energy. However, because the second charging cable section is relatively short, line losses and energy consumption for cooling are kept to a minimum. On the other hand, a short second charging cable section naturally also means a small operating radius, so vehicles to be charged must always be brought as close as possible to the second charging cable section, at the end of which the charging plug is located.

[0016] DE 10 2018 122 663 A1 discloses a cable feed arrangement for electrically powered motor vehicles. The arrangement comprises an electrical cable for charging an energy storage device of the motor vehicle, which is arranged on a support arm. The support arm has a trolley for positioning the cable and is horizontally movable. The trolley is located at a height above the motor vehicle to be charged. A free end of the cable hangs from the trolley on the support arm to be connected to the motor vehicle from above for charging. The cable is liquid-cooled.

[0017] DE 102017 119 930 A1 discloses a device for charging at least one electric vehicle. The device comprises at least one stationary power electronics unit that provides a charging current for charging an electric traction energy storage device of an electric vehicle. Furthermore, the device comprises a horizontally extending or horizontally extendable support and at least one horizontally movable charging point supported by the support. The charging point is electrically connected to the stationary power electronics unit and has at least one charging cable with a charging plug for providing the charging current.

[0018] US 2024 / 0131944 A1 discloses an overhead charging system for electric vehicles. The system comprises a rail mounted above a row of parking spaces and trolleys movable along the rail. A single EV charger is mounted on the trolleys and moves with them. The system also includes a device for electrically connecting the EV charger to a power source without interfering with the movement of the trolleys along the rail. The rail spans two adjacent rows of side-by-side parking spaces.

[0019] DE 10 2017 118299 A1 discloses a charging station for providing electrical energy for an electrically powered vehicle. The charging station comprises a safety charging cable device with a first charging cable segment, a second charging cable segment, and a multi-part safety coupling. The safety coupling electrically and mechanically connects the first and second charging cable segments. It has a first coupling unit, a second coupling unit, and a connection module. The coupling units are equipped with plug-in elements that establish an electrically conductive connection between the charging cable segments.

[0020] US 2011 / 0074351 A1 describes a system for charging electric vehicles that is particularly suitable for parking garages. The system comprises a rail positioned at a height above the vehicle to be charged, a trolley with a movable roller that moves along the rail, a fixed roller, and a power cable. The cable is routed around the movable and fixed rollers so that the connector hangs below the rail. A spring-loaded retraction device is connected to the movable roller to move it into a retracted position.

[0021] An overhead charging system for electric vehicles is known from US 2012 / 0013300 A1. The system comprises a rail mounted above two adjacent rows of parking spaces, a pair of trolleys movable along the rail, and a single EV battery charger. The charger is mounted on the trolleys and moves with them. The system also includes a device for electrically connecting the charger to a power source without interfering with the movement of the trolleys. The trolleys can reach the electric vehicles in both rows of parking spaces.

[0022] DE 102018 129 016 A1 discloses a precast concrete component for parking arrangements, in particular parking garages. The component has at least one guide rail configured to movably support at least one charging cable support element. It also comprises at least one charging device fastening arrangement for fastening at least one charging device to the precast concrete component. The charging device is configured for charging electric vehicles. The precast concrete component can be designed as a ceiling component and allows for flexible positioning of the charging device.

[0023] Especially in charging stations for commercial vehicles, it is important to protect the second cable section when not in use, as such stations are often busy with different vehicles, e.g. forklifts for loading and unloading commercial vehicles. On the other hand, the second charging cable section carrying a charging plug should be able to be made available quickly when needed. For this purpose, DE 102022 123 919 A1 proposes a linear holder arranged on the ceiling of a garage or vehicle hall in the manner of a downwardly open U-rail, into which the second charging cable section can be inserted by means of a trolley when not in use and from which it can be lowered when needed. A similar linear holder is known from WO 2022 184 380 A1.

[0024] DISCLOSURE OF THE INVENTION

[0025] The solution known from DE 102022 123 919 A1 has proven itself in practice. However, it has been shown that, especially in the commercial vehicle sector, it is often desirable to have greater flexibility regarding charging positions, i.e., the locations where electric vehicles can stop to recharge their batteries. For example, vehicles at logistics yards reverse onto a loading ramp for loading or unloading, but are then parked a few meters away from the ramp for fire safety reasons if they do not continue driving immediately. A trivial solution to this problem would be to make the second charging cable section longer.However, since almost all significant line losses in a charging cable with a first charging cable section with a large line cross-section for the most loss-free conduction of current at the current intensities occurring in the respective application and a light second charging cable section occur in the second charging cable section, because the electrical lines therein must necessarily be kept relatively small in cross-section compared to the lines in the first charging cable section due to the necessary handling by people, the second charging cable section should be as short as possible.

[0026] Based on this, the invention is based on the object of providing a charging station that not only enables particularly efficient and low-loss charging of electric vehicles, in particular commercial vehicles, but also offers increased flexibility with regard to the charging positions at which electric vehicles can stop for charging. The invention is also based on the object of providing a retrofittable coupling unit for existing charging stations in order to convert these charging stations so that they also enable particularly efficient and low-loss charging with high flexibility with regard to charging positions.

[0027] The object is achieved by a charging station having the features of claim 1 or a retrofittable coupling unit having the features of claim 11. Advantageous embodiments and further developments are the subject of the subclaims.

[0028] A charging station for electric vehicles according to the invention comprises a converter, a charging cable for establishing an electrical connection between the converter and an electric vehicle to be charged, an adapter unit, a linear receptacle arranged remote from the floor, and a linear guide. The charging cable comprises a first charging cable section with a first cable cross-section and a second charging cable section and a second charging cable section with a second cable cross-section, wherein the second cable cross-section is smaller than the first cable cross-section. The first charging cable section and the second charging cable section are connected to one another via the adapter unit. The adapter unit is arranged at one end of the linear receptacle. The linear receptacle serves to accommodate the second charging cable section when not in use. The linear guide slidably supports the linear receptacle and the adapter unit.A linear guide is understood to be a guide element with the help of which the linear mount and the adapter unit can be moved relative to the ground. It comprises a guide part, e.g. a rail, and a traveling part that can move along the guide part and by means of which the linear mount and the adapter unit are slidably attached to the guide part. This advantageously allows the second charging cable section, or more precisely its free end, at which a charging plug is located that is to be connected to a vehicle to be charged, to be moved to different positions, while at the same time keeping the second charging cable section relatively short. The converter, which often generates considerable heat and / or noise and, depending on its output, also requires a relatively large amount of space, can be arranged far away from the adapter unit. In this case, part of the first charging cable section can be laid in a fixed location.The invention therefore allows the converter to be positioned away from the vehicle in a fire-protected manner and to optimize the space required for parking and maneuvering the vehicles.

[0029] It should be noted that when we briefly talk about a "charging cable section with a cable cross-section", we naturally mean the sum of the cable cross-sections of the electrical cables contained therein, since such a charging cable typically always contains several electrical cables.

[0030] Depending on their design and weight, the linear mount and the adapter unit can be moved mechanically, hydraulically, or by electric motor along the linear guide. The means for retracting the second charging cable section into the linear mount when not in use can also be operated mechanically, hydraulically, or by electric motor. The adapter unit can be attached to the linear mount and, via this, to the moving part; however, it can also be provided that the linear mount is attached to the adapter unit and, via this, to the moving part. The adapter unit and linear mount can also be attached directly to the moving part, and separate (but synchronously moved) moving parts can be provided for the adapter unit and linear mount. The moving part does not have to be a separate component; it can, for example, be permanently attached to the linear mount.

[0031] The linear receptacle offers several advantages over cable-retracting systems. Its low installation height is particularly advantageous for the electrification of existing depots for diesel-powered vehicles, as such depots often have low ceiling heights. Furthermore, a linear receptacle does not require rotary unions or sliding contacts, which has a positive effect on reliability, efficiency, and costs. Furthermore, the second charging cable section undergoes only a slight bend when being pulled into and lowered from the linear receptacle. The radius of this bend can be precisely defined by a corresponding guide roller in the linear receptacle and adapted to the type of cable used for the second charging cable section, ensuring that the cable is not subjected to excessive stress by bending.

[0032] In a preferred embodiment, the guide part of the linear guide is mounted on the ceiling of a vehicle hall or vehicle shelter. It should be noted here that the term "ceiling" refers not only to full-surface ceilings, but also to elements such as supports and beams of garages, halls, open shelters, and similar scaffolding and structures for temporarily storing vehicles.

[0033] In another preferred embodiment, the guide part of the linear guide is arranged on or in a boom of a support structure or is formed by a part of the boom. This advantageously allows for a wide variety of installation situations and allows charging stations according to the invention to be efficiently installed even in halls whose ceiling height significantly exceeds the height of the vehicles to be charged, so that arranging the linear guide on the hall ceiling would require excessively long cables, or in halls whose ceilings have only low load-bearing capacities.

[0034] If a support structure with a boom is used, this can be designed to pivot about at least one axis, similar to a construction crane. Alternatively or additionally, the support structure can comprise a mast that is essentially vertical when properly installed. If such a mast is provided, a section of the first charging cable section can be guided within the mast.

[0035] In a further preferred embodiment, a section of the first charging cable section is guided in the linear guide, in particular in a Z-shape. This advantageously makes it particularly easy to ensure that the adapter unit can remain coupled to the first charging cable section even when the linear holder is moved along the linear guide. It should be noted that this type of cable routing is commonly referred to as Z-shaped, but that in reality, appropriate bends generally do not result in two parallel cable sections that are connected in a Z-shape via a diagonally running cable section, but rather three essentially parallel cable sections. Nevertheless, following common usage, such a cable routing is referred to as Z-shaped here.

[0036] In a preferred embodiment, the first charging cable section is formed by an uncooled cable and the second charging cable section is formed by a fluid-cooled cable. This makes it possible to use electrical cables with relatively small cross-sections in the second charging cable section. Although these cables heat up more than electrical cables with larger cross-sections, they are relatively lightweight despite the coolant lines required and are therefore easy to handle. The invention advantageously allows the person skilled in the art to select a solution for the second charging cable section that is optimally tailored to the respective application situation and to find a compromise between handleability and power loss. The arrangement of the second charging cable section away from the ground already means that it is generally easy to handle, since its weight is primarily borne by the linear mount orthe parts arranged therein that carry the charging cable section, such as a trolley or the like, and operators do not have to pick up the charging cable section, for example, from the ground.

[0037] If the second charging cable section is formed by a fluid-cooled cable, it can be provided that the adapter unit comprises a coolant pump and a coolant recooling unit. This advantageously allows the components required for cooling the second cable section to be arranged on the second cable in a simple and compact manner, eliminating the need for separate housings and long supply and return lines for coolant. The coolant recooling unit can comprise active or passive heat exchangers and means for dissipating heat, such as fans. The coolant pump and, if applicable, the coolant recooling unit (if this requires power) can advantageously be supplied with electrical energy via the first cable section. For this purpose, any converters / dividers required can then be provided in the adapter unit, since units such as the coolant pump or fan are typically not operated with the high charging currents supplied via the first cable section.

[0038] Suitable cables for forming the cooled cable section are shown in the already mentioned DE 10 2022 123 919 A1, so that reference can be made to this in this respect.

[0039] A retrofittable coupling unit for electric vehicle charging stations according to the invention comprises: a charging cable for establishing an electrical connection between a converter and an electric vehicle to be charged, wherein the charging cable has a first charging cable section with a first cable cross-section and a second charging cable section with a second cable cross-section, wherein the second cable cross-section is smaller than the first cable cross-section, an adapter unit for connecting the first charging cable section to the second charging cable section, a linear holder which can be mounted remotely from the floor for receiving the second charging cable section when not in use, at one end of which the adapter unit can be arranged, and a linear guide for displaceably holding the linear holder and the adapter unit.

[0040] With such a coupling unit, existing charging stations can be converted in a simple and cost-effective manner so that line losses are minimized while maximizing the charging current. This is done by selecting appropriate cable cross-sections to design the first charging cable section for virtually loss-free conduction of charging current, while limiting the length of the second charging cable section.

[0041] In a preferred embodiment of the retrofittable coupling unit, a guide part of the linear guide is designed for mounting on a ceiling of a vehicle hall or a vehicle shelter.

[0042] In another preferred embodiment, the retrofittable coupling unit comprises a support structure with a boom, on or in which a guide part of the linear guide can be arranged or which forms a guide part of the linear guide. In this case, one or more of the following features can optionally be provided individually or in combination: the boom is pivotable about at least one axis, the support structure comprises a mast that is essentially vertical in the intended assembled state, wherein the mast is preferably designed to receive a section of the first charging cable section, a section of the first charging cable section is guided in the linear guide, in particular in a Z-shape.

[0043] In a further preferred embodiment of the retrofittable coupling unit, the first charging cable section comprises an uncooled cable, and the second charging cable section comprises a fluid-cooled cable. In such an embodiment, the adapter unit can then be provided with a coolant pump and a coolant recooling unit, wherein the coolant pump and, if applicable, the coolant recooling unit can preferably be supplied with electrical energy via the first cable section.

[0044] Further details and advantages of the invention will become apparent from the following purely exemplary and non-limiting description of an embodiment in conjunction with the four figures. BRIEF DESCRIPTION OF THE DRAWING

[0045] Fig. 1 shows a schematic diagram of a charging station according to the prior art.

[0046] Fig. 2 shows schematically a coupling unit according to the invention in a first working position.

[0047] Fig. 3 shows schematically a coupling unit according to the invention in a second working position.

[0048] Fig. 4 shows schematically a coupling unit according to the invention in a rest position.

[0049] DESCRIPTION OF PREFERRED EMBODIMENTS

[0050] In the drawings, parts with the same function have been given the same reference symbols, and a repeated description of parts already described has been avoided as far as possible.

[0051] Fig. 1 schematically shows a charging station according to the prior art known from DE 102022 123 919 A1, which is arranged partially on or in a building with a wall 10 and a ceiling 12 (only partially shown). Another part of the charging station, namely a converter 14, is located some distance from the building. The converter 14 is typically supplied with three-phase current via a primary power cable 16. Converter electronics 18 provided in the converter 14 rectifies the supplied alternating voltage and generates a direct current suitable for charging the batteries in the electric vehicles to be charged.

[0052] Via a first charging cable section 20, the direct current is fed to an adapter unit 22 fastened to the wall 10, from where it can be fed to a vehicle to be charged via a cooled second charging cable section 24 with a charging plug 26 shown exaggeratedly large in the figure. When the three-phase alternating current is converted into direct current by the converter electronics 18, a power loss dependent on the level of the charging current occurs when charging the electric vehicles. This power loss leads to the converter electronics 18 heating up and thus to the converter 14 as a whole. The heat generated by the power loss can be continuously dissipated by suitable measures in order to protect the converter electronics 18. The heat can be used advantageously, e.g. for heating industrial or drinking water.

[0053] By spatially separating converter 14 and adapter unit 22, the space required for converter 14 can be relocated to an area where it does not obstruct walkways or driveways, and the heat generated by converter 14 due to power losses can be easily dissipated. Furthermore, the high three-phase voltage supplied, typically in the kilovolt range, can be transformed to the lower charging voltage far away from areas where people are present, significantly reducing the electrical safety measures required.

[0054] Both the primary power cable 16 and the first charging cable section 20 are sufficiently generously dimensioned with regard to the cross-sectional areas of the electrical lines contained therein, i.e. the so-called line cross-sections, in order to keep the heating caused by ohmic losses in the lines as low as possible in the respective application (so that one can speak of a practically loss-free line) and thus increase the overall efficiency of the charging station. The energy saved by avoiding cable-related power losses then increases the energy available for charging batteries. The second charging cable section 24 should be flexible and light enough to be handled by people, which is why the electrical lines in the second charging cable section 24 must be relatively thin. Such restrictions do not apply to the first charging cable section 20.Typically, the first charging cable section 20 is formed by a heavy, thick, and largely rigid underground cable, the conductors of which have such a large cross-section that no significant electrical losses and thus no significant heating occur, even at charging currents in the hectoampere and kiloampere range. Advantageously, the first charging cable section 20 is also laid underground as far below a base 28 so that it is cooled by the surrounding earth.

[0055] In the charging station shown according to the prior art, the adapter unit 22 serves to electrically connect the first charging cable section 20 to the second charging cable section 24. It houses a coolant pump (not shown) to pump coolant through the second charging cable section 24 during operation of the charging station.

[0056] In order to cool the coolant circulating in the second charging cable section 24 during operation, the charging station according to the prior art is provided with a separate heat exchanger 30 arranged on the outside of the wall 10, which is connected to the adapter unit 22 via heat exchanger inflow lines 32 and heat exchanger outflow lines 34.

[0057] The known adapter unit 22 has a programmable electronic control unit 36 ​​which monitors and controls charging processes. For this purpose, corresponding signal and control lines can be provided in the second charging cable section 24, via which control lines the control unit 36 ​​can communicate with corresponding sensors and actuators, for example on the charging plug 26 and / or on a charging socket of a vehicle to be charged, in order to ensure, for example, that the charging plug 26 and charging socket are correctly connected and locked. Depending on the type of connection, it can be provided that not only an electrical connection to a vehicle to be charged can be established via the charging plug 26, but also a fluid connection for coolant to the vehicle, so that, for example, a charging socket and in particular the batteries of the vehicle to be charged, which heat up during charging, can be cooled.

[0058] The charging station according to the prior art shown in Fig. 1 further comprises a linear receptacle 38, which essentially has the shape of a U-profile open towards the floor 28, in which movable, in particular displaceable or pivotable, holding hooks are arranged, which support the second charging cable section 24 along the linear receptacle close to the ceiling and are moved to lower the second charging cable section 24. For this purpose, the holding hooks can, for example, be pivoted in one after the other in order to release a part of the second charging cable section 24 at a time, i.e. to no longer have any contact with the charging cable section 24, or can be pushed against one another like curtain hooks, so that the second charging cable section 24 always remains in contact with the holding hooks, but the distances between the holding hooks change.

[0059] In the charging station shown in Fig. 1, the second charging cable section 24 is pulled in and lowered into the linear receptacle 38 by means of a trolley 42 operated by a motor 40.

[0060] Figures 2 to 4 schematically show an embodiment of a coupling unit for charging stations according to the invention, designated as a whole by 50, in various positions. The coupling unit comprises a support structure formed by a mast 52, a boom 54, and a supporting cable 56. To clarify the cable routing, both the mast 52 and the boom 54 are shown partially transparent in the schematic representation of Fig. 2 in order to illustrate the basic course of a first, uncooled charging cable section 20, which in this embodiment is routed through the mast 52 and the boom 54. Below the mast 52, the first charging cable section 20 is then routed to a converter, analogous to the representation in Fig. 1.

[0061] In the embodiment shown, the first charging cable section 20 is guided from the mast 52 via a first bend 58 into the boom 54, where it is guided via a second bend 60 and a third bend 62 to an adapter unit 22. As already explained above, this type of cable routing is commonly referred to as Z-shaped, although the cable section between the bends 58 and 60, the cable section between the bends 60 and 62, and the cable section between the bend 62 and the adapter unit 22 run essentially parallel.

[0062] In this exemplary embodiment, the adapter unit 22 is arranged at one end of a linear receptacle 38. The linear receptacle 38 serves to accommodate a second charging cable section 24, which is cooled in the embodiment shown, when not in use, and the second charging cable section 24 is connected to the first charging cable section 20 via the adapter unit 22. The adapter unit 22 advantageously comprises a coolant pump and a coolant recooling unit, with ventilation grilles 64 visible in the figure through which heat can escape from the adapter unit 22. To improve the recooling and heat dissipation, the coolant recooling unit can comprise one or more fans, which, like the coolant pump, can then be supplied with electrical energy via the first cable section 20.

[0063] A special feature of the invention is that the linear mount 38 and the adapter unit 22 are movably arranged on a linear guide. The linear guide comprises a guide part 66 and a moving part 68 movable along the guide part, via which the linear mount 38 and the adapter unit 22 are movably attached to the guide part 66. This advantageously makes it possible to move the second charging cable section 24, more precisely its free end, at which a charging plug 26 to be connected to a vehicle to be charged is located, to different positions, while simultaneously keeping the second charging cable section 24 relatively short.

[0064] In this embodiment, the guide part 66 of the linear guide is formed by a substantially rail-shaped section of the boom 54. The linear mount 38 and the adapter unit 22 can be moved along the guide part 66 mechanically, hydraulically, or by electric motor. Likewise, the means for retracting the second charging cable section 24 into the linear mount 38 when not in use can be operated mechanically, hydraulically, or by electric motor. In the embodiment shown, a traction cable 70 is provided for moving a trolley 42. If the trolley is moved to the left in Figures 2 to 4, it presses the second charging cable section 24 into the linear mount 38, where it is supported by retaining hooks 72, only a few of which have been provided with reference numerals for reasons of clarity.If the trolley is moved to the right in Figures 2 to 4, it opens the retaining hooks 72 one after the other, so that the second charging cable section 24 and in particular the charging plug 26 are lowered.

[0065] The retaining hooks 72 and the mechanism for releasing or holding the second charging cable section 24 in the linear guide 38 can be designed differently and, for example, be spring-loaded into a closed position and opened by the passing of the trolley 42 in order to release a part of the second charging cable section 24. They can also be pushed against one another like curtain hooks, so that the second charging cable section 24 always remains in contact with the retaining hooks, but the distances between the retaining hooks change. The linear holder 38 and the adapter unit 22 can also be moved along the linear guide, more precisely along the guide part 66 of the linear guide, via the pull cable 70. The trolley 42 can be held in its respective position by suitable, known locking mechanisms that are released by actuating the pull cable 70.Instead of a pull cable 70, a control unit can also be suspended in such a way that it can be easily grasped, via which corresponding servo motors can then be actuated to move the linear guide 38 and the adapter unit 22 and to lower or retract the second charging cable section 24.

[0066] If a motorized adjustment is provided for moving the linear guide 38 and the adapter unit 22 and / or for lowering or retracting the second charging cable section 24, the corresponding adjustments can be made via pull cables or other mechanisms such as threaded rods.

[0067] The adapter unit 22 can be attached to the linear mount 38 and, via this, to the moving part 68. However, it can also be provided that the linear mount 38 is attached to the adapter unit 22 and, via this, to the moving part 68. The adapter unit 22 and the linear mount 38 can also be attached directly to the moving part 68, and separate (but synchronously moved) moving parts can be provided for the adapter unit 22 and the linear mount 38. The moving part 68 does not have to be a separate component, but can, for example, be fixedly arranged on the linear guide 38.

[0068] Compared to the working position shown in Fig. 2, in the working position shown schematically in Fig. 3, the adapter unit 22 and linear holder 38 are moved far outwards along the guide part 66, i.e. away from the mast 52. Fig. 4, in contrast, shows a rest position in which the second charging cable section 24 is pulled into the linear holder and the adapter unit 22 and linear holder 38 are brought into a position close to the mast. In Figures 3 and 4, only some parts of the coupling unit 50 have been provided with reference numerals and the mast and boom are not shown partially transparent, but the cable route corresponds to that shown schematically in Fig. 2, wherein the total length of the first cable section 20 received in the boom 54 remains constant, but the lengths of the individual cable sections between the bends 58, 60 and 62 and the adapter unit 22 change.

[0069] Numerous modifications and further developments are possible within the scope of the inventive concept, for example, relating to the design and attachment of the linear guide. For example, instead of the illustrated cantilever, a guide part of the linear guide can also be mounted directly on the ceiling of a vehicle hall or vehicle shelter. If a cantilever is used, it can be pivotable about at least one axis.

[0070] Advantageously, the person skilled in the art can select a length for the second charging cable section that is optimally adapted to the respective application in order to optimize energy consumption and charging time. The efficiency of a charging station according to the invention can be optimized by selecting the largest possible cross-section of the cables in the second charging cable section, taking into account the manageability of the second charging cable section. This minimizes power loss and, if the second charging cable section is formed by a cooled cable, the energy required for cooling. Since the second charging cable section is suspended, the charging plug can be quickly moved away from the area in which vehicles and people move when not in use, thus protecting it from damage.By appropriately dimensioning the length of the second charging cable section, it can also be advantageously ensured that it can never fall to the ground, but rather, even when the second charging cable section has been extended as far as possible from the linear receptacle, it will still hang slightly above the ground. This is particularly important for charging plugs with liquid cooling, as these can easily break or at least be severely damaged if, for example, they are pulled out of a vehicle's charging socket at the end of a charging process and accidentally dropped to the ground. The charging station or charging device according to the inventionThe retrofittable coupling unit allows for minimizing power loss and the resulting heat generation during charging processes, optimizing equipment footprints around the vehicles being charged, simplifying the handling of charging cables, removing heat sources such as transformer stations and rectifiers from the area of ​​the vehicles being charged, and increasing fire safety. Charging stations and coupling units according to the invention are ideally suited for electrifying existing vehicle depots with low ceiling heights. Since they do not require rotary unions or sliding contacts, they offer high reliability at optimized costs.

[0071] LIST OF REFERENCE SYMBOLS

[0072] 10 Wall

[0073] 12 Ceiling

[0074] 14 converters

[0075] 16 primary power cable

[0076] 18 Converter electronics

[0077] 20 first charging cable section

[0078] 22 Adapter unit

[0079] 24 second charging cable section

[0080] 26 charging cable plugs

[0081] 28 Floor

[0082] 30 heat exchangers

[0083] 32 Heat exchanger inflow line

[0084] 34 Heat exchanger drain line

[0085] 36 Control unit

[0086] 38 Linear recording

[0087] 40 engine

[0088] 42 trolley

[0089] 50 coupling unit

[0090] 52 masts

[0091] 54 booms

[0092] 56 suspension cable

[0093] 58 Bend Bend Bend Ventilation grille Guide part Driving part Pull rope Retaining hook

Claims

PATENT CLAIMS 1. Charging station for electric vehicles with a converter (14), a charging cable (20, 24) for establishing an electrical connection between the converter (14) and an electric vehicle to be charged, wherein the charging cable (20, 24) has a first charging cable section (20) with a first cable cross-section and a second charging cable section (24) with a second cable cross-section, wherein the second cable cross-section is smaller than the first cable cross-section, an adapter unit (22) for connecting the first charging cable section (20) to the second charging cable section (24) and a linear receptacle (38) arranged remote from the floor for receiving the second charging cable section (24) when not in use, characterized in that the linear receptacle (38) and the adapter unit (22) are arranged displaceably on a linear guide (66, 68).

2. Charging station according to claim 1, characterized in that a guide part (66) of the linear guide (66, 68) is arranged on a ceiling (12) of a vehicle hall or a vehicle shelter.

3. Charging station according to claim 1, characterized in that a guide part (66) of the linear guide (66, 68) is arranged on or in a boom (54) of a support structure (52, 54, 56) or is formed by a part of the boom (54).

4. Charging station according to claim 3, characterized in that the boom (54) is pivotable about at least one axis.

5. Charging station according to claim 3 or 4, characterized in that the support structure (52, 54, 56) comprises a mast (52) which is substantially vertical in the intended assembled state.

6. Charging station according to claim 5, characterized in that a section of the first charging cable section (20) is guided in the mast (52).

7. Charging station according to one of claims 1 to 6, characterized in that a section of the first charging cable section (20) is guided in the linear guide (66, 68), in particular in a Z-shape.

8. Charging station according to one of claims 1 to 7, characterized in that the first charging cable section (20) is formed by an uncooled cable and the second charging cable section (24) is formed by a fluid-cooled cable.

9. Charging station according to claim 8, characterized in that the adapter unit (22) comprises a coolant pump and a coolant cooling unit.

10. Charging station according to claim 9, characterized in that the coolant pump and, if applicable, the coolant cooling unit are supplied with electrical energy via the first cable section (20).

11. Retrofittable coupling unit (50) for electric vehicle charging stations, comprising a charging cable (20, 24) for establishing an electrical connection between a converter (14) and an electric vehicle to be charged, wherein the charging cable has a first charging cable section (20) with a first cable cross-section and a second charging cable section (24) with a second cable cross-section, wherein the second cable cross-section is smaller than the first cable cross-section, an adapter unit (22) for connecting the first charging cable section (20) to the second charging cable section (24), and a linear receptacle (38) that can be mounted remotely from the floor for receiving the second charging cable section (24) when not in use, at one end of which the adapter unit (22) can be arranged, characterized by a linear guide (66, 68) for the displaceable mounting of the linear holder (38) and the adapter unit (22).

12. Retrofittable coupling unit (50) according to claim 11, characterized in that a guide part (66) of the linear guide (66, 68) is designed for mounting on a ceiling (12) of a vehicle hall or a vehicle shelter.

13. Retrofittable coupling unit (50) according to claim 11, further comprising a support structure (52, 54, 56) with a boom (54) on or in which a guide part (66) of the linear guide (66, 68) can be arranged or which forms at least part of the guide part (66) of the linear guide (66, 68).

14. Retrofittable coupling unit (50) according to claim 13, characterized by at least one of the following features individually or in combination: the boom (54) is pivotable about at least one axis, the support structure (66, 68) comprises a mast (52) which is essentially vertical in the intended assembled state, wherein the mast is preferably designed to receive a section of the first charging cable section (20), a section of the first charging cable section (20) is guided in the linear guide (66, 68), in particular in a Z-shape.

15. Retrofittable coupling unit (50) according to one of claims 11 to 14, characterized in that the first charging cable section (20) is formed by an uncooled cable and the second charging cable section (24) is formed by a fluid-cooled cable.

16. Retrofittable coupling unit (50) according to claim 15, characterized in that the adapter unit (22) comprises a coolant pump and a coolant recooling unit, wherein preferably the coolant pump and optionally the coolant recooling unit can be supplied with electrical energy via the first cable section (20).

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