Plug connector, cable, charging current distributor and energy hub

Abstract

The invention relates to a plug connector (100; 200; 300; 400; 506) having at least one first (108; 212) and one second electrical conductor (110; 214) for direct current and at least one first optical fibre (112; 216; 310; 410) for transmitting information. The invention further relates to a cable (504) having the plug connector (100; 200; 300; 400; 506), a charging current distributor (502) having the cable (504), and an energy hub (500) having a plurality of cables (504) or a plurality of charging current distributors (502). The invention also relates to a use of the plug connector (100; 200; 300; 400; 506).

Description

[0001] NAME OF THE INVENTION

[0002] Connectors, cables, charging current distributors and energy hubs

[0003] AREA OF INVENTION

[0004] The present invention relates to a connector, a cable with the connector, a charging current distributor with the cable, an energy hub and a use of the connector for charging an electric micro-vehicle.

[0005] STATE OF THE ART

[0006] Connectors are used to disconnect or connect electrical or optical lines. Connection points between such lines are often created by positive-locking mechanisms to align the connector parts correctly. Additionally, connectors can incorporate friction-locking mechanisms. These friction-locking mechanisms include, for example, bayonet fittings or screw connections. Connectors are frequently categorized by their shape as plugs, sockets, couplers, or receptacles. Based on their function, connectors are often distinguished between those for transmitting electrical signals or power and those for transmitting optical signals or power.

[0007] Charging connectors are a subgroup of connectors used for transmitting electrical energy. They are used to connect to mobile devices to electrically charge their batteries and / or directly supply power to their connected devices. Specific types of charging connectors include electric vehicle charging connectors for charging electric vehicles and charging connectors for mobile devices to provide either direct power or a buffered power supply via a battery storage system.

[0008] Improvements in lithium batteries during the 1990s and 2000s led to the rapid development of electric vehicles, particularly electric bicycles, light vehicles, micromobility vehicles, and small electric vehicles. Small electric vehicles include electric scooters and Segways. WO 2024052620 A1 discloses a connector system for producing a hybrid electrical / optical contact. The known system comprises a socket and a plug, each plug comprising a plug body and an insulator, the interior of which contains an electrical contact. The electrical contact includes an optical insert in its center, containing an optical contact and an optical fiber; each optical contact is mounted on the optical fiber and includes an optical sensor.

[0009] TASK OF INVENTION

[0010] The object of the invention is to create an inexpensive connector that can be safely plugged in and unplugged while reducing or avoiding arcing, and is therefore particularly suitable as a charging connector for cost-effective charging of electric bicycles, light vehicles, micromobility vehicles or small electric vehicles.

[0011] REVELATION OF THE INVENTION

[0012] According to the invention, a connector according to claim 1 is provided. The connector according to the invention preferably comprises at least one first and one second electrical conductor for direct current and at least one first optical conductor for transmitting information.

[0013] A connector is generally used to disconnect or connect electrical or optical lines. The connector according to the invention can have a positive-locking connecting element to align the first and second electrical conductors appropriately opposite each other with a further connector. This "appropriately opposite alignment" can include bringing the first and second electrical conductors into an electrically conductive connection with a third and a fourth electrical conductor, respectively. The connector preferably includes a projection or a groove that can serve as an anti-rotation device.

[0014] The connector according to the invention can have a friction-fit connecting element. The friction-fit connecting element preferably comprises a screw connection. In other words, the connector according to the invention can have a screw connection. The screw connection includes, for example, a thread. In other words, the connector according to the invention can have a bayonet or threaded device. Preferably, the threaded device is designed such that the connector must be rotated approximately 0.25 times, or a quarter turn, about its longitudinal axis to lock or unlock the connector according to the invention with respect to the other connector.Alternatively or additionally, the connector according to the invention can have a locking means, wherein the locking means preferably comprises: a counter-pressure spring, snap lock with a detent lug or a clip, lever mechanism, magnetic lock, a push-pull lock, and / or a clamping bracket.

[0015] The connector according to the invention can have a first electrical plug contact, which is arranged at one end of the first electrical conductor and can be electrically connected to the first electrical conductor. The connector according to the invention can have a second electrical plug contact, which is preferably arranged at one end of the second electrical conductor and can be electrically connected to the second electrical conductor.

[0016] The first optical fiber preferably comprises an optical waveguide, an optical fiber, an optical waveguide made of transparent plastic such as polymethyl methacrylate, polycarbonate, or a polymer optical fiber. Preferably, the first optical fiber has a core diameter of approximately 1 mm to couple the radiation from an inexpensive light-emitting diode instead of an expensive laser diode. The first optical fiber can include an optical lens or a lens connector. The lens can be arranged at one end of the optical fiber or optical fiber output and collimate the light to couple it into a lens opposite the connector, refocus it there, and couple it into another optical fiber. An advantage of lenses or lens connectors is their insensitivity to axial misalignment between the connector according to the invention and the other connector. A further advantage of lenses or lens connectors is their ability to prevent interference with the optical fiber.Lens plugs are insensitive to impurities.

[0017] The information transmitted on the first optical fiber comprises, in particular, a signal. The signal comprises a continuous signal. More preferably, the signal comprises a modulated signal. When the connector according to the invention is disconnected from the further connector, the signal is preferably modified or interrupted. In other words, when the connector according to the invention is connected to the further connector, the transmitted information comprises, in particular, connection information. When the connector according to the invention is disconnected from the further connector, the transmitted information comprises, in particular, disconnection information. The connection information and the disconnection information are preferably different. If the connector is disconnected or unplugged from the further connector while energized, an arc flash could occur. An arc flash could also occur when the connector is plugged in.An electric arc can cause burns to a user, wear and tear on connector components, short circuits, and / or an increased risk of fire. The connection and / or disconnect information can be used to de-energize the connector according to the invention before it is plugged in or unplugged, thus reducing or preventing an electric arc.

[0018] According to a further embodiment, the connector according to the invention can have a second optical fiber for transmitting information. The first and second optical fibers can act as forward and return conductors to transmit the signal to the second connector and receive a response signal from the second connector.

[0019] According to a further embodiment, the connector according to the invention can include an optical feedback device. According to a further embodiment, the optical feedback device can comprise an optical reflector or a transmission optical fiber.

[0020] The connector according to the invention and / or the further connector can include the optical feedback device. In other words, the optical feedback device is arranged in or integrated into the further connector. The connector according to the invention can include the further connector. The optical reflector can include a mirror. The optical reflector is designed to reflect the signal. If the connector according to the invention is disconnected from the further connector, one conductor end of the first optical fiber does not reflect the signal or reflects it only slightly. If the connector according to the invention is connected to or inserted into the further connector, the conductor end of the first optical fiber and the optical feedback device are preferably arranged parallel to each other or abutting each other. The optical feedback device reflects the signal back into the first optical fiber.The first optical fiber can carry a superimposed signal consisting of a forward signal and a reflected return signal. This superimposed signal can provide connection information. In a further embodiment, the optical feedback device comprises, in particular, an optical fiber loop or a transmission optical fiber. The optical fiber loop is essentially a section of optical fiber with a first and a second conductor end. The optical fiber loop is preferably a short section of optical fiber—so short that it can be integrated into the connector according to the invention or into the further connector. The first and second conductor ends of the optical fiber loop are arranged in the further connector according to the invention such that they are opposite, parallel, or abutting the conductor ends of the first optical fiber and the second optical fiber of the connector according to the invention or into the further connector.If the connector according to the invention is connected to or plugged into the other connector, the signal from the first optical fiber can be guided via the optical fiber loop into the second optical fiber. The first optical fiber can carry a forward signal, and the second optical fiber carries a return signal, whereby the forward and return signals are essentially the same or constitute connection information. If the connector according to the invention is disconnected from or unplugged from the other connector, the second optical fiber essentially carries no return signal. A missing return signal in the second optical fiber can constitute disconnection information.

[0021] The friction-fit connection and the optical feedback devices can interact advantageously. The friction-fit connection can ensure a connector disconnection time t1 when the connector is mechanically disconnected or unplugged, where the transmission of the disconnection information requires a time t2, and where t1 > t2. In other words, the technically determined time for mechanically disconnecting the connector allows the interruption of the information in the optical fiber to occur quickly enough to de-energize the connector and prevent or reduce an arc.

[0022] Advantages of an optical feedback device, such as a mirror and a fiber optic loop, include its particularly low technical complexity, its robustness, its low component cost, and / or the minimal effort required to integrate the optical feedback device into the connector. If, as is common in conventional connectors, circuits or sensors are used instead to determine connection or disconnection information, the technical complexity, component cost, and integration effort can increase, and the robustness can decrease. According to a further development, the connector according to the invention includes an electrical protective conductor. A protective conductor is essentially an electrical conductor used for safety purposes, for example, to protect against electric shock.

[0023] Preferably, the connector is essentially cylindrical. The first electrical contact comprises a first cylindrical base sector and a first cylindrical shell section. The second electrical contact comprises a second cylindrical base sector and a second cylindrical shell section. The first and second contacts are electrically separated by an insulator. The insulator essentially comprises two further cylindrical base segments and two further cylindrical shell sections, respectively arranged between the first and second cylindrical base sectors and between the first and second cylindrical shell sections.

[0024] Preferably, the conductor end of the first optical fiber is arranged perpendicular to the surface of a cylindrical base segment of the insulator. A recess is preferably provided in the cylindrical base segment of the insulator so that the conductor end of the first optical fiber can be coupled to the optical feedback element in the subsequent connector. Preferably, the conductor end of the second optical fiber is arranged perpendicular to the surface of another cylindrical base segment of the insulator. A recess is preferably provided in this further cylindrical base segment of the insulator so that the conductor end of the second optical fiber can be coupled to the optical feedback element in the subsequent connector.

[0025] The protective conductor preferably comprises a disc-shaped plug contact. The disc-shaped plug contact is arranged centrally or concentrically on the cylindrical base of the plug connector.

[0026] Preferably, a DC voltage of 50 to 5000 V is present between the first and second electrical contacts when the connector according to the invention is connected to the other connector. When the connector according to the invention is not connected to the other connector, preferably a DC voltage of 0 V is present between the first and second contacts.

[0027] According to a further development, the connector according to the invention preferably comprises an electrically insulating receptacle. The connector according to the invention, or the further connector, can each be designed as a plug or male connector or as a socket or female connector. Preferably, the socket comprises the electrically insulating receptacle. The electrically insulating receptacle is a cylindrical area that can prevent accidental contact between the plug contacts or live parts during insertion.

[0028] In a further embodiment, the connector according to the invention comprises a contact sensor. The contact sensor can generate additional connection information when the connector according to the invention is connected to the other connector. The contact sensor can generate additional disconnection information when the connector according to the invention is disconnected from the other connector. The contact sensor can comprise: an electrical switch, an electrical push button, a Hall sensor, a reed sensor, an inductance sensor, a photodiode, a phototransistor, a laser sensor, a fiber optic sensor, or a capacitive sensor. The additional connection information and the additional disconnection information can advantageously be used as a redundant information source alongside the connection or disconnection information of the first optical fiber. The contact sensor essentially increases the reliability of the connector.

[0029] In a further embodiment, the first optical fiber can be arranged spirally surrounding the first and second electrical conductors and act as a fiber optic sensor. In particular, the first optical fiber includes an intrinsic fiber optic sensor. In other words, the first optical fiber itself can act as a sensor. The first optical fiber can act as a fiber optic pressure sensor. In this fiber optic pressure sensor, pressure-induced bending losses can lead to changes in transmission within the optical fiber. This change in transmission can be evaluated by a pressure gauge. Based on this evaluation, the pressure gauge can detect connector damage, connector degradation, and / or indicate the need for predictive maintenance.

[0030] According to a further embodiment, a cable is provided, in particular with the connector according to the invention. The cable is essentially a multi-core assembly of individual conductors surrounded by an insulating material. The cable preferably comprises the first and second electrical conductors for direct current and the first optical fiber for transmitting information. In other words, the connector and the cable can form a cable system or a charging cable. The first optical fiber of the cable can form a fiber optic pressure sensor to determine whether the cable is broken or otherwise damaged. Preferably, the charging cable comprises the connector according to the invention with at least one first and one second electrical conductor and at least one first optical fiber for transmitting disconnection and connection information.

[0031] Preferably, a DC charging system for charging a small electric vehicle or other DC consumer comprises in a further embodiment:

[0032] a first connector with

[0033] o at least one first and one second electrical conductor and o one first optical fiber and / or

[0034] a second optical fiber for transmitting separation and connection information and

[0035] another connector with an optical reflector or a transmission light guide,

[0036] wherein, when the first connector and the further connector are connected, a connection signal is present in the first and / or second optical fiber, and wherein, when the first connector and the further connector are disconnected, a disconnection signal is present in the first and / or second optical fiber.

[0037] In another embodiment, a charging current distributor can comprise a charging station and the cable. Preferably, the charging current distributor comprises several cables or several charging cables. In a further embodiment, an energy hub can comprise several cables or several charging current distributors. The energy hub can comprise a charging park, also called a charging hub. A charging park is essentially a publicly accessible facility for charging electric vehicles.

[0038] Preferably, the energy hub comprises more than 50, more than 100, or even more than 200 cables or charging cables or charging current distributors. The connector according to the invention essentially has very cost-effective components; that is, it does not require special or expensive sensors, circuits, and the like. Large, cost-efficient energy hubs with many charging cables can thus be manufactured for charging small electric vehicles, e.g., electric scooters, other DC consumers, DC devices, or DC storage systems.

[0039] Functionally, the connector, cable, charging current distributor, and / or energy hub according to the invention, together with the first and second optical fibers and / or the optical feedback device, essentially constitute a technically simple current-disconnecting device. Conventional connectors or charging cables are usually locked in a complex manner during a charging process to prevent unintentional connection. A dangerous arc flash can occur when a live connector is plugged in or unplugged. The conventional locking mechanism prevents this and ensures that the connector or charging cable is de-energized at the end of a charging process before it is unplugged or disconnected from the unit being charged. Such conventional mechanisms are complex, expensive, and require extensive maintenance. The connector, cable, charging current distributor, and / or energy hub according to the invention...The energy hub can form a technically simple power cut-off, thus reducing or preventing an arc when plugging in or unplugging.

[0040] Pressure gauges for fiber optic sensors are usually expensive. The energy hub can have a switching matrix that is connected to several charging cables in a switchable manner. The switching matrix can also be connected to a pressure gauge and connect the pressure gauge sequentially or intermittently to individual charging cables to measure the pressure of an optical fiber within the charging cable.

[0041] According to a further embodiment, the connector according to the invention can be used for charging a small electric vehicle. Such small electric vehicles include, in particular, electric scooters and motorcycles. The connector according to the invention can also be used for supplying direct current in an industrial environment, e.g., for connecting to an electric motor, a machine, a milling machine, a conveyor belt, a robot, a photovoltaic system, a battery, or a wind turbine. Furthermore, the connector according to the invention can be used for charging or supplying power to other direct current consumers. Other direct current consumers include, for example: LED lighting systems, computers, smartphones, tablets, electric boat drives, heating devices, server racks, telecommunications systems, mobile phone base stations, or power tools. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Exemplary embodiments of the invention are explained in more detail with reference to the drawings and the following description. The drawings show:

[0043] Figure 1 shows an embodiment of a plugging device according to the invention, Figure 2 shows a further embodiment of a plugging device according to the invention,

[0044] Figure 3 shows a further embodiment of a plug-in device according to the invention,

[0045] Figure 4 shows a further embodiment of a plug-in device according to the invention and

[0046] Figure 5 shows an embodiment of an energy lift according to the invention.

[0047] FORMS OF EXECUTION OF THE INVENTION

[0048] Figure 1 shows a sectional view of a socket 100. The socket 100 forms a plug connection. It comprises a cylindrical plug body 102 made of an insulating material, e.g., plastic. The socket 100 also includes a cylindrical recess 104, which forms a socket opening and is arranged in the plug body 102 such that a plug can be held securely in it. Furthermore, the socket 100 includes an internal thread 106. The cylindrical recess 104 has a first plug contact and a second plug contact at its base. The first plug contact is electrically connected to a first electrical conductor 108; the second plug contact is electrically connected to a second electrical conductor 110. The first and second electrical conductors 108 and 110 are arranged in a cable. The socket 100 also includes a fiber optic cable segment 112, the ends of which open into the base of the cylindrical recess 104.The fiber optic cable section 112 forms an optical feedback device or an optical transmission light guide. The socket 100 further comprises at least one PE or protective conductor contact 114 arranged on the internal thread 106 and a protective conductor 116. The protective conductor contact 114 is electrically connected to the protective conductor 116. The length of the cylinder of the recess 104 is designed as a safety feature such that an arc is extinguished before an unplugged connector can leave the recess. In other words, the axial length of the recess 104 is selected depending on the arc path during the insertion or removal of a connector. The fiber optic cable section 112 serves as a feedback device for a connector equipped with corresponding fiber optic cables. The internal thread 106 allows 0.25 to 1.75 turns to force-fit the connector to the socket 100.The internal thread is designed to accommodate a typical user rotation speed and the duration of an optical signal transmission through the fiber optic cable section 112 and the fiber optic leads of the connector. When the connector is pulled or unplugged from the socket, the fiber optic leads of the connector are disconnected from the fiber optic cable section 112. A detection device on the connector can detect the absence of an optical feedback signal and de-energize the connector before it is completely removed from the recess 104. This reduces or prevents arcing.

[0049] The bushing 100 can have an anti-rotation device, e.g. a locking lug or groove and / or a counter-pressure spring to secure a locking position.

[0050] Socket 100 forms a DC charging socket for an e-scooter.

[0051] Figure 2 shows a plug 200. The plug 200 comprises a plug body 202. Furthermore, an external thread 204 is arranged at the first end of the plug body 202, which serves as a frictional locking element to detachably connect the plug to a corresponding socket. A cylindrical multipole plug contact 206 projects from the external thread 204. The multipole plug contact 206 comprises a positive pole 208 and a negative pole (in Fig.

[0052] (2 not visible). The positive and negative terminals 208 are designed as cylindrical segments and form electrical plug contacts. An insulator 210 is arranged between the negative and positive terminals. The positive terminal 208 is electrically connected to a first electrical conductor 212; the negative terminal is electrically connected to a second electrical conductor 214. Furthermore, the connector 200 includes a first fiber optic cable 216, which forms a forward line and transmits an optical signal to the multi-pole plug contact 206. The connector 200 includes a second fiber optic cable 218, which forms a return line and transmits a reflection or feedback of the optical signal away from the multi-pole plug contact 206. An evaluation device at the end of the second fiber optic cable 218 can evaluate the optical signal or the return signal and, depending on this, determine whether the connector is connected to a socket (connection information) or disconnected from it (disconnection information).When a disconnect signal is present, this causes the plug 200 to be de-energized, thus reducing or preventing an arc when plugging it into or unplugging it from the socket. The plug 200 comprises at least one protective conductor contact 220 arranged on the external thread 204 and a protective conductor 222. The protective conductor contact 220 is electrically connected to the protective conductor 222.

[0053] Connector 200 is connected to a cable. The cable contains lines 212, 214 and fiber optic lines 216, 218.

[0054] The 200 plug may have an anti-rotation device, e.g. a locking tab or groove.

[0055] Figure 3 shows a front view of a socket 300 forming a connector. The socket 300 comprises a cylindrical recess 302 for receiving a plug, a positive terminal 304, a negative terminal 306, an insulator 308, a transmission glass fiber 310, and two protective conductor contacts 312. The socket 300 also includes an anti-rotation feature, in particular a groove or spring.

[0056] Figure 4 shows a front view of a plug 400, which forms a connector. The plug 400 comprises a multi-pole contact 402 for insertion into a corresponding socket, a positive terminal 404, a negative terminal 406, an insulator 408, a first optical fiber 410, a second optical fiber 412, and two protective conductor contacts 414.

[0057] Figure 5 shows an energy hub 500 for charging e-scooters, comprising a central unit or charging current distributor 502 with several charging cables 504, each with a charging plug 506. The charging plugs 506 correspond to the plugs 200. The central unit 502 includes at least one DC-DC converter 508 and a fiber optic pressure sensor 510. The charging cables 506 are arranged along a two-pole DC bus 512 and electrically connected to it. Each charging cable has a protective conductor. The DC bus 512 is electrically connected to the DC-DC converter 508.

[0058] 100 sockets

[0059] 102 plug-in units

[0060] 104 cylindrical recesses

[0061] 106 internal threads

[0062] 108 first electrical line

[0063] 110 second electrical line

[0064] 112 fiber optic cable sections

[0065] 114 PE or protective conductor contact

[0066] 116 Protective conductor

[0067] 200 plugs

[0068] 202 plug-in bodies

[0069] 204 external threads

[0070] 206 multi-pole plug contact

[0071] 208 Positive pole

[0072] 210 Insulator

[0073] 212 first electrical line

[0074] 214 second electrical line

[0075] 216 first fiber optic cable

[0076] 218 second fiber optic cable

[0077] 220 Protective conductor contact

[0078] 222 Protective conductor

[0079] 300 socket

[0080] 302 cylindrical recess

[0081] 304 Positive pole

[0082] 306 Negative terminal

[0083] 308 Insulator

[0084] 310 T transmission glass fiber

[0085] 312 protective conductor contacts

[0086] 400 plugs

[0087] 402 multi-pole plug connector

[0088] 404 Positive pole

[0089] 406 Negative terminal

[0090] 408 Insulator

[0091] 410 first fiber optic cable 412 second fiber optic cable

[0092] 414 protective conductor contacts

[0093] 500 energy hubs

[0094] 502 Central unit

[0095] 504 charging cables

[0096] 506 charging plugs

[0097] 508 DC-DC converter 510 fiber optic pressure gauge 512 DC-DC converter

Claims

REQUIREMENTS 1. Connectors (100; 200; 300; 400; 506) with at least one first (108; 212) and one second electrical conductor (110; 214) for direct current and at least one first optical fiber (112; 216; 310; 410) for transmitting information.

2. Connectors (100; 200; 300; 400; 506) according to claim 1 with a second optical fiber (218; 412) for transmitting information.

3. Connectors (100; 200; 300; 400; 506) according to claim 1 or 2 with an optical feedback device (112; 310).

4. Connectors (100; 200; 300; 400; 506) according to claim 3, wherein the optical feedback device (112; 310) comprises an optical reflector or a transmission optical fiber (112; 310).

5. Connectors (100; 200; 300; 400; 506) according to one of the preceding claims with an electrical protective conductor.

6. Connectors (100; 200; 300; 400; 506) according to any of the preceding claims with a bayonet or threaded device (106; 204).

7. Connector according to one of the preceding claims with an electrically insulating socket (104; 302).

8. Connectors (100; 200; 300; 400; 506) according to any of the preceding claims comprising a contact sensor.

9. Connector (100; 200; 300; 400; 506) according to any one of the preceding claims, wherein the first optical fiber (112; 216; 310; 410) is arranged spirally surrounding the first (108; 212) and second electrical conductor (110; 214) and acts as a fiber optic sensor.

10. Cable (504) with a connector (100; 200; 300; 400; 506) according to any one of the preceding claims.

11. Charging current distributor (502) with a cable (504) according to claim 10.

12. Energy hub (500) with multiple cables (504) according to claim 10 or with multiple charging current distributors (502) according to claim 11.

13. Use of a connector (100; 200; 300; 400; 506) according to any one of claims 1 to 9 for charging an electric micro-vehicle.

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