Temperature sensor for a power distributor

Abstract

The invention relates to a temperature sensor (2), the shape of which corresponds to a component (10, 11), for which a receiving location (12, 13) is provided on the power distributor (8), such that the temperature sensor (2) is receivable at the receiving location (12, 13) on the power distributor (8), wherein electrical contacts of the receiving location (12, 13) are then galvanically isolated by the temperature sensor (2), and wherein the temperature sensor (2) is configured to measure a temperature in the region of the receiving location (12, 13). The component (10, 11) may, for example, be a standardized blade fuse for a vehicle.

Description

[0001] 24-1902

[0002] TEMPERATURE SENSOR FOR A POWER DISTRIBUTION BOX

[0003] The present invention relates to the field of power distribution units, which can be used, for example, in vehicles. In particular, the invention relates to a temperature sensor for a power distribution unit, a system for measuring the temperature at a power distribution unit, and a vehicle with such a system.

[0004] Power distribution boards in vehicles serve to direct electrical energy from the battery or generator to various electrical consumers. They can, for example, be designed as circuit boards with slots for plug-in fuses, which are connected to the vehicle's electrical system via busbars. Power distribution boards heat up during operation due to factors such as the load currents flowing through them, increased electrical resistance at contact points, insufficient heat dissipation, or ambient temperatures. Uncontrolled heating can lead to material fatigue, malfunctions, or even fires.

[0005] PTC (Positive Temperature Coefficient) or NTC (Negative Temperature Coefficient) resistors are frequently used as sensors to monitor component temperatures in power distribution units. These resistors change their electrical resistance depending on the temperature, thus enabling measurement. The sensors can be attached to the power distribution unit in various ways, for example, using cable lugs, soldering, or gluing.

[0006] These measurement methods can detect temperature increases, for example due to increased contact resistance or high currents, in order to prevent damage or overheating. However, these separate temperature sensors must be attached to the power distribution unit being measured using special applications. Furthermore, they require additional installation space and prior technical modifications to the power distribution unit being measured; in other words, implementation is complex, especially with existing power distribution units.

[0007] It is an object of the present invention to provide a temperature sensor for a power distribution unit which is simple and space-saving, and can be used in particular with existing and common power distribution units, especially in vehicles. 24-1902

[0008] The solution to this problem is achieved according to the teaching of the independent claims. Various embodiments and further developments of the invention are the subject of the dependent claims.

[0009] A first aspect of the invention relates to a temperature sensor which in its form corresponds to a component for which a receiving position is provided on the power distributor, such that the temperature sensor can be received at the receiving position on the power distributor, wherein electrical contacts of the receiving position are then galvanically isolated by the temperature sensor, wherein the temperature sensor is configured to measure a temperature in the area of ​​the receiving position.

[0010] The term "vehicle" as used here refers specifically to a passenger car, including all types of motor vehicles, hybrid and battery-powered electric vehicles, as well as vehicles such as sedans, vans, buses, trucks, delivery vans, and the like. The term "electric vehicle" then refers specifically to electric or hybrid vehicles, particularly vehicles that are at least partially powered by an electric motor. An (electric) vehicle can be, in particular, a passenger car, but also a vehicle such as a van, bus, truck, delivery van, and the like, or a two-wheeler, such as an (electric) motorcycle, (electric) scooter, e-bike, e-scooter, and the like.

[0011] The terms “comprises”, “includes”, “includes”, “indicates” may be used here 1The terms "has," "with," or any other variant thereof are intended to cover non-exclusive inclusion. For example, a method or apparatus that includes or comprises a list of elements is not necessarily limited to those elements but may include other elements not expressly listed or inherent in such method or apparatus.

[0012] Furthermore, unless expressly stated otherwise, “or” refers to an inclusive or and not an exclusive “or”. For example, a condition A or B is satisfied by one of the following: A is true (or present) and B is false (or not present), A is false (or not present)24-1902

[0013] and B is true (or present), and both A and B are true (or present).

[0014] The terms "ein" or "eine," as used here, are defined as "one or more." The terms "ein anderer" and "ein Weitere," as well as any other variant thereof, are to be understood as "at least one more."

[0015] The term "plural", as used here, is to be understood in the sense of "two or more".

[0016] For the purposes of this invention, the terms "configured" or "set up" (and their respective variations) to perform a specific function mean that the device is already in a configuration or setting capable of performing the function, or at least that it is adjustable—i.e., configurable—so that it can perform the function after appropriate adjustment. Configuration can be achieved, for example, by adjusting parameters of a process sequence or by using switches or similar devices to activate or deactivate functionalities or settings. In particular, the device can have several predetermined configurations or operating modes, allowing configuration to be performed by selecting one of these configurations or operating modes.

[0017] The invention is therefore based on the provision of a temperature sensor that utilizes the installation space of another component, in particular a standardized component. For this purpose, the temperature sensor is connected to the power distribution unit at a mounting location that is actually intended for the other component. Such mounting locations can be present in greater numbers on the power distribution unit, for example as sockets for plug-in fuses, whereby at least one or a few of these locations are usually left free as spare locations. A temperature sensor or several temperature sensors can be mounted at such a location or locations, since their shape corresponds to the component, i.e., in particular their external shape, such as form and size.24-1902

[0018] The mounting point where the temperature sensor connects to the power distributor typically has electrical contacts, as this point is actually intended for the other component. For example, the mounting point might be a fuse holder, in which case the two contacts are connected via the fuse. However, according to the present invention, the temperature sensor is intended to measure only the temperature at the relevant point on the power distributor, thus avoiding any interference with the power distributor's electrical circuitry. This is achieved by galvanically isolating the electrical contacts of the power distributor's mounting point within the temperature sensor.

[0019] Therefore, no physical modifications to the power distribution unit are necessary, as the temperature sensor fits precisely into a mounting location originally intended for another component. This allows for flexible use even with existing power distribution units. Mounting can be simple and mechanically stable, using the same method as the other component, for example, by inserting or screwing it in. The temperature sensor is configured to measure a specific temperature at a particular point on the power distribution unit, specifically at the point where it connects. Multiple temperature sensors can also be installed at different locations on the power distribution unit, each measuring a specific temperature.

[0020] Power distribution units can be mounted on busbars. Busbars are metal conductors, usually made of copper or aluminum, that can transmit high currents with low resistance and serve as a central distribution point for electrical power. Busbars can also heat up, but this cannot be detected, or only inadequately detected, by temperature sensors on the distribution units. Due to contact points that extend into the distribution unit, temperature measurement at a point on a busbar connected to the distribution unit is also possible.

[0021] Preferred embodiments of the temperature sensor according to the first aspect are described below, each of which, unless expressly excluded or technically impossible, can be combined arbitrarily with each other and with 24-1902

[0022] can be combined with the other described aspects of the invention.

[0023] In some embodiments, the temperature sensor comprises a housing part containing the sensor's electronics, which are configured to be connected to an evaluation unit, and a mounting part configured to engage with the power distributor at the mounting location, and a temperature probe connected to the sensor's electronics. It is understood that in these embodiments, both the housing part and the mounting part correspond in shape to the respective parts of another component, such as a fuse, for which the mounting location is actually designed.

[0024] The temperature sensor allows for particularly accurate temperature measurement inside the power distribution box. This is not the case with separate temperature sensors mounted on the top of the distribution box, as these measure surface temperature. In particular, this method improves temperature measurement of a busbar, since the temperature sensor is positioned inside the distribution box and thus in close proximity to the busbar.

[0025] In some related embodiments, the temperature sensor is designed as a connector, the connecting part having a first and a second contact extending from the housing and configured to be inserted into a standardized socket of a power distribution unit, the contacts being galvanically isolated within the housing. The contacts can be metallic, for example, metal pins or flat contacts made of a metal sheet. They can extend essentially parallel. Installing a connector is particularly simple. It is understood that the connector, with its contacts, fits into corresponding sockets of the receiving socket.

[0026] In some embodiments, one of the plug contacts includes the temperature sensor, or one of the plug contacts is designed as a temperature sensor. In some embodiments, the electronics of the temperature sensor are connected via a 24-1902

[0027] The plug contacts can be supplied with power. Generally, even if the temperature sensor is not designed as a plug, it can be designed so that the temperature sensor's electronics can be powered via one of the plug contacts. This eliminates the need for a separate power connection for the temperature sensor. The electrical current can be drawn directly from the power distribution box.

[0028] In some embodiments, the temperature sensor corresponds in shape to a standardized fuse, so that the temperature sensor can be accommodated in a standardized mounting location of a power distributor for a fuse, for example by inserting or screwing it into the mounting location.

[0029] In some embodiments, the temperature sensor corresponds in shape to a standardized flat fuse for a vehicle, so that the temperature sensor can be received, in particular plugged in, at a standardized slot of a power distributor for a vehicle.

[0030] Blade fuses (also called "plug-in fuses") are standardized fuses for vehicles, inserted into electrical distribution slots via two metal contacts. They consist of a plastic housing with an integrated fusible link that burns out in case of overcurrent, thus interrupting the circuit. Various standardized sizes exist, including Micro, Mini (Form F), Standard (ATO or Form C), Maxi Compact (Form L), and Maxi (Form E), which differ in their dimensions and permissible current ratings. The corresponding slots in electrical distribution boxes consist of metal spring contacts that ensure an electrical connection. They are often arranged in groups.

[0031] Since spare slots are usually provided, i.e., free slots, these can be used for temperature sensors of the present invention, provided they correspond in shape to known blade fuses. In particular, several temperature sensors can be installed at different locations on the power distribution unit, as several spare slots are usually available. This allows the temperature to be measured selectively at different points. 24-1902

[0032] A second aspect of the invention relates to a system for measuring a temperature on a power distributor, comprising at least one temperature sensor according to the first aspect and an evaluation unit which is connected to the temperature sensor and is configured to receive and evaluate a temperature signal from the temperature sensor.

[0033] The temperature signal is generated primarily by the electronics of the temperature sensor, specifically based on a temperature measured by the sensor. A signal line for transmitting the temperature signal can be routed to the evaluation unit via a wiring harness interface, which is usually already available.

[0034] In some embodiments of the system, the evaluation unit is further configured to evaluate the temperature signal by comparing a detected temperature with at least one threshold value and issuing a warning signal if the threshold value is exceeded. In particular, a warning signal can control an output unit that issues a visual and / or audible warning about an (excessively) high temperature, especially together with an indication of where the temperature increase occurs.

[0035] In some embodiments of the system, the evaluation unit is further configured to generate a control signal to activate the power distributor, parts thereof, and / or electrical components connected to the power distributor when the temperature signal indicates that a temperature exceeds a threshold value. This activation can, in particular, include switching off the power distributor or, for example, reducing power to lower the temperature or prevent impending overheating. Since the temperature measurement, as described, can be performed very precisely at the power distributor, activation, such as switching off the power distributor, can also be performed with corresponding precision. Electrical components connected to the power distributor can, for example, include the vehicle's electrical system or parts thereof, and / or electrical components supplied with power via the electrical system.The control can also be carried out in such a way that the control signal is sent to a control unit24-1902.

[0036] is transmitted, which then takes over the corresponding control, such as switching off.

[0037] A third aspect of the invention relates to a vehicle with an on-board power supply system, which has at least one power distributor and at least one system for measuring a temperature at the power distributor according to the second aspect.

[0038] The features and advantages explained in relation to the first aspect of the invention also apply accordingly to the other aspects of the invention.

[0039] Further advantages, features and possible applications of the present invention will become apparent from the following detailed description in conjunction with the drawings.

[0040] This shows:

[0041] Fig. 1 shows a system for measuring the temperature of a power distributor according to one embodiment, comprising a temperature sensor and an evaluation unit; and

[0042] Fig. 2 shows an exploded view of a power distribution unit with blade fuses and busbars.

[0043] The same or analogous reference numerals are used throughout the figures for the same or corresponding elements of the invention. Some aspects depicted are not shown to scale in the figures.

[0044] Fig. 1 schematically shows a system 1 for measuring the temperature of a power distribution unit. The system comprises a temperature sensor 2, which is connected to an evaluation unit 3.

[0045] The temperature sensor 2 corresponds in shape to a standardized blade fuse, which are commonly used in electrical distribution systems for vehicles. In the present case, the temperature sensor 2 corresponds in shape, i.e., its external shape, in particular in form and size, to a standardized blade fuse (“ATO” or Form C). It is understood that this is merely an example.24-1902

[0046] The temperature sensor 2 can also correspond in its shape to another component which is actually or also mounted on the power distributor, in particular a standardized component, such as a standardized blade fuse, which can be available in different sizes.

[0047] Figure 2 shows an exploded view of a power distribution unit 8. This unit is designed to be connected to busbars 9, in particular to be plugged onto them. The power distribution unit 8 can be integrated into the electrical system of a vehicle (not shown) by means of the busbars 9 in order to distribute electrical energy, for example from a battery to various consumers. Accordingly, the numerous electrical connections made via the power distribution unit 8 are designed to be protected by appropriate fuses, for example with known fuse links of the types described below.

[0048] The power distribution box 8 has a number of corresponding mounting positions 12 for standard ATO blade fuses 10. These can also be referred to as slots, and the blade fuses as plug-in fuses. In addition, further mounting positions 13 are provided for mini plug-in fuses 11.

[0049] As can be seen in Fig. 2, not all mounting positions 12, 13 are occupied by blade fuses 10, 11. A number of mounting positions 12, 13 remain free, for example, for reserve purposes. These can now be used for temperature sensors according to the present invention. For example, the temperature sensor 2 shown in Fig. 1, in ATO format, can be installed in any of the mounting positions 12. In particular, several temperature sensors 2 can thus be distributed via the power distributor 8 in order to measure a specific temperature at the respective location. Since the temperature sensor 2 corresponds in shape to a blade fuse, it can easily be integrated into existing systems with power distributors 8. No additional installation space is required.

[0050] Referring again to Fig. 1, the temperature sensor 2 has a mounting element in the form of two plug contacts 5, 6. These flat 24-1902

[0051] The metal contacts, as explained, correspond in shape to those of a standard blade fuse. Since the temperature sensor 2 should not affect the further function of the power distributor 2, the two plug contacts 5 and 6, and thus the corresponding electrical contacts of a mounting position 12, are galvanically isolated. One of the plug contacts, here for example plug contact 5, serves as a temperature sensor, which is connected to an electronics unit 4 of the temperature sensor 2. This unit is located in a housing part 7 of the temperature sensor 2 and is connected to the evaluation unit 3.

[0052] A corresponding temperature signal with a measured temperature is transmitted to evaluation unit 3, where the temperature is compared, for example, with a threshold value. If the temperature is too high, i.e., above the threshold value, a warning signal can be issued and / or further measures can be taken, such as switching off components affected by overheating. 24-1902

[0053] REFERENCE MARK LIST

[0054] 1 System for measuring temperature at a power distribution box 2 Temperature sensor

[0055] 3 evaluation unit

[0056] 4 Electronics

[0057] 5, 6 Mounting part (plug contacts)

[0058] 7 Housing part

[0059] 8 current collectors

[0060] 9 busbars

[0061] 10 blade fuses (ATO)

[0062] 11 blade fuses (mini)

[0063] 12 admission places (ATO)

[0064] 13 recording stations (Mini)

Claims

24-1902 REQUIREMENTS 1. Temperature sensor (2), which in its form corresponds to a component (10, 11) for which a mounting position (12, 13) is provided on the power distributor (8) such that the temperature sensor (2) can be mounted on the mounting position (12, 13) on the power distributor (8), wherein electrical contacts of the mounting position (12, 13) are galvanically isolated by the temperature sensor (2), wherein the temperature sensor (2) is configured to measure a temperature in the area of ​​the mounting position (12, 13).

2. Temperature sensor (2) according to claim 1, comprising a housing part (7) which houses electronics (4) of the temperature sensor (2), wherein the electronics (4) are configured to be connected to an evaluation unit (3), and a mounting part (5, 6) which is configured to engage with the power distributor (8) at the mounting location (12, 13), and a temperature sensor which is connected to the electronics (4) of the temperature sensor (2).

3. Temperature sensor (2) according to claim 2, wherein the temperature sensor (2) is designed as a plug, wherein the connecting part has a first plug contact (5) and a second plug contact (6) which extend from the housing part (7) and are designed to be plugged into a standardized socket of a power distributor (8), wherein the plug contacts (5, 6) are galvanically isolated in the housing part (7).

4. Temperature sensor (2) according to claim 3, wherein one of the plug contacts (5, 6) comprises the temperature sensor and / or wherein the electronics (4) of the temperature sensor (2) can be supplied with electrical energy via one of the plug contacts (5, 6).

5. Temperature sensor (2) according to one of the preceding claims, wherein the temperature sensor (2) has the shape of a standardized fuse, such that the temperature sensor (2) can be accommodated in a standardized mounting location of a power distributor (8) for a fuse. 24-1902 6. Temperature sensor (2) according to one of the preceding claims, wherein the temperature sensor (2) corresponds in its form to a standardized flat fuse (10, 11) for a vehicle, such that the temperature sensor (2) can be accommodated on a standardized slot (12, 13) of a power distributor (8) for a vehicle.

7. System (1) for measuring a temperature on a power distributor (8), comprising at least one temperature sensor (2) according to one of the preceding claims and an evaluation unit (3) which is connected to the temperature sensor (2) and is configured to receive and evaluate a temperature signal from the temperature sensor (2).

8. System (1) according to claim 7, wherein the evaluation unit (3) is further configured to evaluate the temperature signal in such a way as to compare a detected temperature with at least one threshold value and to issue a warning signal if the threshold value is exceeded.

9. System (1) according to claim 8, wherein the evaluation unit is further configured to generate a control signal to control the power distributor (8), parts thereof and / or electrical components connected to the power distributor (8).

10. Vehicle with an on-board power supply which has at least one power distributor (8) and at least one system (1) for measuring a temperature at the power distributor (8) according to one of claims 7 to 9.

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