Assembly and method for electrically contacting multiple lined-up connection elements of a superordinate unit

Abstract

The invention relates to an assembly and a corresponding method for electrically contacting multiple lined-up connection elements of a superordinate unit. The assembly according to the invention has a profile rail and a clamping device which are interlockingly and releasably coupled to one another. The profile rail has multiple holes in its lower face, which holes are designed in such a way that the connection elements protrude therethrough when the profile rail is fastened to the superordinate unit. The clamping device has at least one terminal block which is designed in such a way that the terminal block has, on its lower face opposite a connection element, a contact mechanism having at least one contact face which contacts at least portions of the connection element of the superordinate unit in order to make electrical contact.

Description

[0001] Description

[0002] Arrangement and method for electrically contacting a plurality of connected terminal elements of a higher-level unit

[0003] The invention relates to an arrangement and a method for electrically contacting a plurality of connected connection elements arranged in a row of a higher-level unit.

[0004] Electrical connections between individual devices, electrical units, or components of a technical system are most often made via plug connectors, even in the manufacturing and process industries. A plug connector typically consists of two parts: a socket and a plug. In industrial environments, a device, electrical unit, or component can also be connected via one or more terminals or pins, which are arranged, for example, on one side of the device, unit, or component in such a way that they are easily accessible from the outside.

[0005] When a large number of identical devices, electrical units, or components in a technical system are arranged in a row, this can result in a multitude of interconnected connection elements or pins, each of which must be individually electrically contacted to, for example, acquire measured values ​​such as the voltage of the individual devices, units, or components. Examples of devices, electrical units, or components in a technical system with a multitude of interconnected connection elements include batteries, solar modules, sensor arrays, automation equipment, control cabinets, or, in particular, stacks of electrochemical cells.

[0006] An electrolysis cell stack for hydrogen production, also called an "electrolysis stack," typically comprises a large number of electrochemical cells in a horizontal or vertical, stacked arrangement. To monitor the operation of the individual cells, evaluate efficiency, and optimize performance, measurements of the cell voltage of one or more electrolysis cells are taken. This is usually done using cell voltage monitoring devices (CVMs). The CVMs are connected to the individual cells, for example, via plug connectors. Each cell being monitored has its own plug connector. For instance, each cell has a flat blade connector, also known as a blade connector, which consists of a flat, rectangular metal blade, protruding from it for electrical contact.By stacking the individual cells, one or more rows with numerous connection elements are created when arranged appropriately. Electrically contacting these numerous connection elements by plugging in corresponding sockets is usually a time-consuming manual process. Since electrolyzers, in particular, contain large amounts of energy and therefore high electrical currents (typically several kA) during operation, the electrical connection must be protected. This is usually also done manually by inserting fuses into the connecting cables, making it equally time-consuming and laborious. With a stack of electrolysis cells, the overall effort is multiplied due to the large number of connections required. It is crucial that the connecting and measuring leads are not confused, as this could potentially damage the measuring system.Considerable time and expense are incurred in the wiring and connection to the cell stack. Measuring the electrical voltage of individual cells in an electrolysis cell stack or fuel cell stack therefore presents both a technical and economic challenge, as does the reliable and permanent connection and contacting of a large number of cells and the protection of the connections against overcurrents, which can occur, for example, due to short circuits, ground faults, or cross-circuits.

[0007] From the prior art, DE 10 2020 212 592 A1 discloses a separator plate, a fuel cell stack, and a method for manufacturing a separator plate, which includes a lateral connection area with a connection element that is at least partially conically shaped to form an insertion cone for a plug connector of a cell voltage monitoring device. Despite simplifying the plug connector, the connection is not reliable because only the insertion of the plug connector is facilitated, and no securing mechanism is provided. Furthermore, a safety device must be manually inserted into the measuring line to achieve an electrically secure connection.

[0008] The present invention is therefore based on the objective of providing an arrangement and a corresponding method for electrically contacting a plurality of connected elements in a series of a higher-level unit, which allows a safe, simple and reliable electrical connection of the unit with another unit, in particular a monitoring unit.

[0009] This problem is solved by an arrangement having the features of claim 1. Furthermore, the problem is solved by a method having the features of claim 10 and by using the arrangement for operating a technical plant according to claim 14. Advantageous embodiments are described in the dependent claims.

[0010] The basic idea of ​​the invention is to adapt and use standard components for electrical contacting in such a way as to achieve a high degree of pre-assembly. The components are modified so that a multitude of connected elements arranged in a row can be easily electrically contacted by a higher-level unit. The arrangement according to the invention comprises a profile rail and a clamping device, which are positively and detachably coupled to one another. The profile rail has a multitude of recesses on its underside, which are designed such that the connecting elements protrude through them when the profile rail is mounted on the higher-level unit.The clamping device has at least one terminal block which is designed such that the terminal block has a contact mechanism on its underside opposite one of the connection elements, with at least one contact surface which touches the connection element of the superior unit at least partially for electrical contact.

[0011] The innovative use of prefabricated parts, such as the profile rail adapted to the array of connection elements of the higher-level unit, in conjunction with a clamping device with terminal blocks, each containing a contact mechanism also adapted to the array of connection elements, results in significantly improved contacting of the numerous arrayed connection elements. The modular design allows for quick and reliable installation, minimizing the likelihood of installation errors and leading to a cost-effective solution that significantly reduces the complexity of the connections and the associated effort. The invention thus enables the use of standard components that are easily adapted to the array of connection elements.It can be used advantageously both during the initial installation of individual electrical devices, electrical units or components of a technical system, and during maintenance work.

[0012] In a particularly advantageous embodiment, the contact mechanism is designed such that a connecting element of the higher-level unit is at least partially enclosed by two opposing contact surfaces. These contact surfaces are designed as springs or connected to springs to increase and permanently maintain the pressure of the contact surfaces on the connecting element. This embodiment allows for particularly reliable contacting of a connecting element. The contact surfaces can, for example, be designed as metal strips or wire springs. The connecting element to be enclosed is located between the two contact surfaces. When the contact surfaces are compressed by the external force of the springs, the connecting element is held in place between them.The springs or spring-like structures ensure that constant pressure is exerted on the connecting element to guarantee a secure, stable, and durable connection. Depending on the application, various materials, shapes, and sizes of the contact surfaces of the contact mechanism can be used.

[0013] In a further advantageous embodiment of the invention, each terminal block of the clamping device further comprises at least one electrical fuse and at least one wiring unit for connecting at least one signal transmission line. In this embodiment, the signal path for the electrical signal runs from the contact mechanism of the terminal block via the fuse to at least one of the wiring units. A terminal block with an integrated fuse and wiring unit represents an attractive solution for electrical connections, as various functions are combined in a single component. The integration of the fuse saves space and prevents excessively high currents from damaging the terminal block and subsequent monitoring units, thus minimizing further hazards such as the risk of fire. The wiring unit simplifies the cabling process.It is not necessary to use separate terminals for the fuse and the wiring, which saves time and effort. If the fuse is integrated and replaceable, the entire terminal block does not need to be replaced during maintenance. Even if the fuse is not integrated and replaceable, there is still an advantage if the terminal block comprises multiple terminal blocks. In this case, a single terminal block can be replaced, rather than the entire block.

[0014] In a preferred embodiment, the wiring unit features an insertion aid for connecting a single- or multi-pole signal transmission line. This significantly simplifies the wiring of numerous connection elements of a higher-level unit. Particularly in the case of stacked electrochemical cells (as the higher-level unit), this can considerably reduce the effort required to wire the large number of cells. Examples of insertion aids for wiring units for connecting a single- or multi-pole signal transmission line include simple slots or openings in combination with spring-loaded terminals or screw terminals. Push-in terminals are particularly advantageous, as they allow for quick and economical wiring even without the need to actuate a screw or spring.In another particularly advantageous design variant, several terminal blocks are coupled together to form blocks, allowing the connection of a predetermined number of terminal elements. This further simplifies the work process and offers, in particular, high flexibility and adaptability to specific requirements. Blocks with a specific number of terminal blocks, from one to n, can be created (e.g., 4, 8, 12, 16, 24...). The number of terminal blocks can be selected, for example, based on the number of conductors in the multi-pole connecting cable. It is also conceivable to base the number of terminal blocks on the number of channels of measuring devices for cell voltage monitoring in electrochemical cells (e.g., Siemens Simatic ET200 MP).When grouping terminal blocks into blocks, spacers and end plates can be advantageously placed between the terminal blocks, further adapting the contacting system to external conditions. Thermal expansion of any components can be accommodated in this way. The handling of the contacting device can also be improved, if necessary.

[0015] In a further embodiment of the invention, a cover provides mechanical protection for the individual wires and terminals. This cover can be made of insulating material or metal. It is advantageous if the cover can be attached to the profile rail and opened.

[0016] In a particularly advantageous embodiment, the higher-level unit is a stack of electrochemical cells, in particular an electrolysis cell stack or a fuel cell stack, in which each cell has at least one laterally projecting connection element for current conduction. All embodiments of the invention are advantageous in these applications. The arrangement according to the invention allows for the simple and efficient establishment of numerous electrical connections to each individual cell, for example, to check the cell voltage. The contacting of the electrochemical cells must be reliable and permanent. Due to the high currents that can flow in the event of a fault, each connection must be protected. Measuring leads must not be confused. All these requirements are met by the arrangement according to the invention.The large number of measuring points significantly reduces the considerable time and cost involved in wiring the stacks. Thanks to the pre-assembled individual components, the arrangement according to the invention is easy to install.

[0017] The object of the present invention is thus also achieved by a method for electrically contacting a plurality of connected elements arranged in a row of a higher-level unit, characterized in that, in a first step, a profile rail with a plurality of recesses on its underside is attached to the higher-level unit such that the connecting elements protrude through the recesses. In a second step, a clamping device is positively and detachably coupled to the profile rail, wherein the clamping device, which comprises at least one terminal block, is placed on the profile rail such that a contact mechanism located on the underside of the terminal block with at least one contact surface touches a connecting element of the higher-level unit for electrical contact, at least partially.Snap-in mechanisms are advantageously used as the coupling mechanism between the mounting rail and the clamping device. Terminal blocks with snap-in mechanisms offer a time-saving, safe, and flexible solution for installing terminals in electrical environments. They simplify wiring, save space, and enable easy maintenance. When several terminal blocks of the clamping device are grouped into a block, this block can be attached to one side of the mounting rail in one piece. After adjusting the contact surfaces, it can be pivoted around the longitudinal axis of the mounting rail so that the device rests against the other side of the mounting rail and is then mechanically coupled to the mounting rail (e.g., by a snap-in mechanism). This can also provide a secure locking or closed position.If required, a block coupled to the profile rail can be fitted with a hood, which can also be hooked onto one side of the profile rail to cover the block after adjustment.

[0018] The previously formulated task is also solved by using an arrangement - as previously explained - for the electrical contacting of a large number of connected terminal elements of an electrolysis cell stack for the production of hydrogen.

[0019] The properties, features, and advantages of this invention described above, as well as the manner in which they are achieved, will become clearer and more readily understandable in connection with the following description of exemplary embodiments, which are explained in more detail in conjunction with the drawings. The drawings show:

[0020] FIG 1 shows a cross-section of an embodiment of the arrangement according to the invention and a perspective view of a profile rail.

[0021] FIG 2 shows a cross-section of an embodiment of the arrangement according to the invention during its assembly and

[0022] Fig. 3 shows a perspective view of an embodiment of the arrangement according to the invention with an indicated exemplary cover. The three figures show cross-sections of the same arrangement; identical parts are therefore provided with the same reference numerals.

[0023] The device 1 according to the invention comprises a profile rail 10 and a clamping device 20. The profile rail 10 can be a commercially available mounting rail for the mechanical fastening of electrical devices according to a DIN standard, for example, DIN EN 60715, with a top hat profile, II, C, or G profile. Commonly used top hat rails, according to the standard, have a width of 35 mm (bottom edge plus the "hat brim") and a height of 7.5 or 15 mm with a material thickness (sheet thickness) of at least 1 mm. Depending on the application, other rail parameters are conceivable. The rail material should be electrically insulating to prevent short circuits. Profile rails often have elongated holes or recesses or slots arranged at regular intervals along the central longitudinal axis of the rail.According to the invention, the recesses are not used, or not only used, for fastening purposes, but also as openings through which connecting elements or pins, which are connected to a higher-level unit, can protrude. Figure 1 below shows a perspective view of a DIN rail 10, which has recesses 15 at regular intervals along the indicated longitudinal axis 11 of the underside 12 of the DIN rail. In this embodiment, these recesses correspond approximately to the width of the underside of the DIN rail. In this embodiment, the distances between the recesses 15 along the longitudinal axis 11 are greater than the length of the recesses themselves. Depending on the application, elongated holes can also be provided along the longitudinal axis 11, which are closely spaced but not as wide.The size and shape of the recesses depend essentially on the connection elements of the higher-level unit that are to be contacted. Figure 1 shows the higher-level unit 100 with a connection element 5. A DIN rail 10 is mounted on the higher-level unit 100. In one application, the arrangement according to the invention is used as the higher-level unit 100 for the electrical contacting of stacked electrochemical cells of an electrolyzer or a fuel cell stack. Here, at least one rectangular flat pin connector (often with dimensions of 6.3 mm width and 0.8 mm thickness or 4.8 mm width and 0.8 mm thickness) is arranged laterally on each cell as an electrical connection element 5. By stacking the individual electrochemical cells, each with a flat pin connector on its side, one or more rows of connection elements are created.The flat pin connectors are usually connected directly or via adapters to a so-called bipolar plate of a cell. In this application, the profile rail of the arrangement according to the invention is mounted on the electrolysis cell stack such that the connection elements protrude through the recesses of the profile rail. The profile rail 10 is positively and detachably coupled to a clamping device 20. The coupling is essentially mechanical. The term "positive locking" refers to a connection or fit between two parts or components in which the shapes or contours are so precisely matched that a firm and stable connection is created. This connection is based on the positive locking, i.e., the exact fit of the shapes, and not on other factors such as adhesives, screws, or welds. Positive locking offers advantages such as high stability, repeatability, and ease of assembly.According to the invention, the positive-locking connection should be detachable, in particular to facilitate the mounting of the clamping device 20 on the profile rail 10. When selecting the rail, requirements regarding a certain load and rotation of the rail when the clamping device is attached to the rail must be taken into account.

[0024] In one embodiment, the clamping device 20 is mounted and secured by snapping it onto the rail (see Fig. 2). This type is particularly suitable for DIN rails or G-rails. The latter is especially advantageous if the clamping device comprises one or more terminal blocks that snap in and out.

[0025] A terminal block is generally an insulating component that supports one or more mutually insulated terminal arrangements and is designed for secure mounting on a mounting surface. A profile rail is typically used as the mounting surface. Examples of such terminal blocks include the 8WH series terminals with push-in connections from Siemens. Unlike conventional terminal blocks, the clamping device 20 has, on the side facing the connection element 5 of the higher-level unit 100, at least one contact mechanism 25 with at least one contact surface that, for electrical contact with the higher-level unit, at least partially touches the connection element. When the clamping device is engaged, the contact surfaces of the connection element and one surface of the contact mechanism are in contact with each other.Sectional contact can be point contact, area contact, or enclosing contact. In principle, all devices that establish electrical connections between two components and enable current flow are considered contact mechanisms for electrical contact. Plugs and sockets are examples of enclosing contacts. It is also conceivable that the contact mechanism has two surfaces which, when the terminal block is engaged, contact the connection element from two opposite sides via spring force. Generally, spring contacts are special contact elements that have a spring-like action. They generate a constant pressure force to establish a reliable electrical connection. Spring contacts enable a reliable, permanent connection despite potential vibrations or temperature fluctuations in the environment.

[0026] From the contact mechanism, integrated power lines 30 in the clamping device lead to at least one wiring unit 35A, 35B for connecting at least one signal transmission line 36. Particularly for applications involving high electrical currents of several kA, the insertion of a fuse 40 into the signal path is advantageous. This can be one or more electrical fuses for overcurrent protection. In some embodiments, the clamping device 20 can be designed such that the fuse 40 is replaceable. For overvoltages, at least one so-called bridge slot (reference numeral 45 in Fig. 2) can be incorporated into the device 20, in which overvoltage protection components such as Zener diodes or varistors can be implemented.

[0027] Advantageously, the 35A and 35B wiring units feature an insertion aid for connecting single- or multi-pole signal transmission lines. Wiring units with an external "push-in" connection are also available. This allows wires to be inserted into the wiring unit without tools. The push-in connections incorporate a spring mechanism. The wire is inserted into the connection, activating the push-in mechanism. Once the wire is inserted, the mechanism locks, and the spring force presses the connection firmly against the wire to create a secure and permanent electrical connection.

[0028] In the embodiment shown in Fig. 1, the clamping device 20 is connected via the wiring unit 35A to a conductor 36 of a multi-core cable 37, which can, for example, be connected to a measuring system. The wiring unit 35B can be used for testing purposes. In the application of contacting an electrochemical cell, for example, it may be necessary to perform temporary comparative measurements on one or more cells via the second wiring unit of the clamping device. For this purpose, the second wiring unit makes it possible to connect an external wire to the "unsecured" side of a terminal.

[0029] Figure 2 illustrates the simple assembly of the clamping device. If the clamping device 20 is designed to have at least one terminal block, it can be hooked onto one side of the profile rail at an angle. After adjusting the contact mechanism, it can be pivoted around the longitudinal axis of the profile rail towards the connection element of the higher-level unit and then come to rest on it. It is important that, before the clamping device 20 is folded down, the terminal block is positioned so that the at least one contact surface 25 of the contact mechanism can at least partially touch the connection element 5 of the higher-level unit 100. For example, locking mechanisms could be used to ensure contact. A corresponding locking lug (not shown) could be provided on the clamping device 20, and a corresponding spring mechanism could be incorporated into the clamping device.It is also conceivable to attach the clamping device using various accessories such as sliding nuts or hook head screws.

[0030] Advantageously, the clamping device 20 comprises several terminal blocks, which can be grouped into blocks. Figure 3 shows an embodiment of such a block 60. In such cases, spacers and / or end plates of different thicknesses can also be used (not shown) to meet the requirements for contacting the higher-level unit. The blocks can be formed in one piece. During assembly, a block 60 can be hooked onto one side of the profile rail 10, and after adjusting the contact surfaces, it can be moved and, in the final step, attached to the other side of the profile rail such that the contact surfaces of the individual contact mechanisms of the block and the connection elements of the higher-level unit touch at least partially. In particularly advantageous embodiments, a block is snap-fitted to the profile rail.

[0031] If required, a block can be fitted with a cover 70 (see Fig. 3), which can also be hooked onto one side of the profile rail 10 to cover the block 60 after adjustment. The cover can be considered a loose housing that is at least partially open at the bottom to allow electrical contact with the connection elements. The cover can be made of insulating material or metal. The cover allows individual blocks to be held together on the profile rail. In the embodiment shown in Fig. 3, a cable gland 75 is also provided in the cover 70 to provide strain relief for the multi-pole connecting cable 37. Thus, the cover 70 offers mechanical protection for the individual wires and terminals. Optionally, a handle can be provided to facilitate the swiveling connection process.Furthermore, the cover allows for locking the contacting device after the connecting leads have been made and wired, thus preventing unauthorized disconnection of the connecting leads. For improved clarity, coding or markings can be provided on individual terminal blocks, blocks, or the cover itself to prevent incorrect insertion of individual leads or incorrect insertion of individual blocks. The cover 70 itself can have a locking mechanism 80 to release the locked position and open the cover.

Claims

Patent claims 1. Arrangement (1) for electrically contacting a plurality of connected terminal elements (5) of a superior unit (100), comprising a profile rail (10) and a clamping device (20) which are positively and detachably coupled to one another, wherein the profile rail (10) has a plurality of recesses (15) on its underside, which are designed such that the terminal elements (5) protrude through them when the profile rail is attached to the superior unit (100), wherein the clamping device (20) has at least one terminal block, which is designed such that the terminal block has a contact mechanism (25) with at least one contact surface on its underside opposite one of the terminal elements (5) and is designed such that the at least one contact surface touches the terminal element (5) of the superior unit at least partially for electrical contact.

2. Arrangement according to claim 1, wherein the contact mechanism (25) is configured such that a connecting element (5) of the superior unit (100) is at least partially enclosed by two opposing contact surfaces, wherein the contact surfaces are configured as a spring or are connected to a spring to increase the pressure of the contact surfaces on the connecting element (5).

3. Arrangement according to claim 1 or 2, wherein the at least one terminal block further comprises at least one electrical fuse (40) and at least one wiring unit (35A, 35B) for connecting a signal transmission line (36, 37), wherein the signal path runs from the contact mechanism (25) of the terminal block via the fuse (40) to at least one of the wiring units (35A, 35B).

4. Arrangement according to claim 3, wherein the wiring unit (35A, 35B) has an insertion aid for connecting a single- or multi-pole signal transmission line (36, 37).

5. Arrangement according to one of the preceding claims, wherein several terminal blocks are coupled to form a block (60) which allows the contacting of a previously defined number of connection elements (5).

6. Arrangement according to claim 5, wherein spacer and end plates are arranged between the terminal blocks.

7. Arrangement according to one of claims 5 or 6, wherein a hood (70) made of insulating material or metal is provided to cover a block.

8. Arrangement according to claim 7, wherein the hood (70) can be hinged and attached to the profile rail (10).

9. Arrangement according to one of the preceding claims, wherein the superior unit (100) is a stack of electrochemical cells, in particular an electrolysis cell stack or a fuel cell stack, wherein each cell has at least one laterally projecting connection element for current dissipation.

10. Method for electrically contacting a plurality of connected elements (5) arranged in a row of a superior unit (100), characterized in that a profile rail (10) with a plurality of recesses (15) on its underside is attached to the superior unit (100) in such a way that the connecting elements protrude through the recesses (15), and that a clamping device (20) is positively and releasably coupled to the profile rail by placing the clamping device (20), which comprises at least one terminal block, on the profile rail (10) in such a way that a contact mechanism (25) located on an underside of the terminal block with at least one contact surface touches a connecting element (5) of the superior unit for electrical contact at least partially.

11. Method according to claim 10, characterized in that the at least one terminal block is further configured such that it has at least one electrical fuse (40) and at least one wiring unit (35A, 35B) for connecting a signal transmission line (36, 37), wherein the signal path runs from the contact mechanism (25) of the terminal block via the fuse (40) to at least one of the wiring units (35A, 35B).

12. Method according to claim 10 or 11, characterized in that several terminal blocks of the clamping device are combined into a block (60), which is attached in one piece to one side of the profile rail (10), and after adjustment of the contact surfaces (5, 25) is pivoted in their direction around the longitudinal axis of the profile rail so that the clamping device rests on the other side of the profile rail, wherein a block (60) can be provided with a hood (70) if required, which can also be attached to one side of the profile rail to cover the block (60) after adjustment.

13. Method according to any one of the preceding claims 10 to 12, wherein the superior unit (100) is configured as a stack of electrochemical cells, in particular as an electrolysis cell stack or fuel cell stack, wherein each cell is configured with a laterally projecting connection element for current dissipation.

14. Use of an arrangement according to any one of claims 1 to 9 for electrically contacting a plurality of connected terminal elements of an electrolysis cell stack for the production of hydrogen.

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