WO2018170905A1

WO2018170905A1 - Electrical equipment for use in electrical or hybrid vehicle

Info

Publication number: WO2018170905A1
Application number: PCT/CN2017/078144
Authority: WO
Inventors: Ronghui Li; Yu Qiu; Jun Liu; Shuisheng YU
Original assignee: Valeo Siemens Eautomotive Shenzhen Co., Ltd.
Priority date: 2017-03-24
Filing date: 2017-03-24
Publication date: 2018-09-27
Also published as: CN109070754B; EP3600941A1; CN109070754A; EP3600941A4

Abstract

An electrical equipment comprises a casing and an electronic control unit (20-2), said electronic control unit (20-2) comprises at least one safety switch (20C) configured for switching off the electronic control unit (20-2) when said at least one safety switch (20C) is released and for switching on the electronic control unit (20-2) when said at least one safety switch (20C) is pressed. The electrical equipment further comprises a pin (40) comprising an elongated body having a proximal end and a distal end, said elongated body being configured so that in a position, called closed position, said distal end abuts against an element (50) of the casing and said proximal end abuts against the at least one safety switch (20C) for switching the electronic control unit (20-2) on.

Description

ELECTRICAL EQUIPMENT FOR USE IN AN ELECTRICAL OR HYBRID VEHICLE

FIELD OF ART

The present invention relates to an electrical equipment, in particular for an electrical or a hybrid vehicle, and relates more particularly to an electrical equipment that can automatically shut down when an operator tries to access the internal components of said electrical equipment, in particular components at high voltage levels, in order to increase the safety of said operator.

The invention aims at providing a simple, reliable and efficient mechanism based on a safety switch mechanism that can be activated or deactivated using a pin.

STATE OF THE ART

In systems comprising circuits which transmit electrical power, including modern vehicle propulsion systems, it is not desirable for an operator to have physical contact with components or systems that are at high voltage levels, for example such as an inverter.

In an existing solution illustrated on Figures 1 and 2, an inverter 1-1 comprises an electric control unit 20-1 and a power module (not shown) mounted into a casing made of a metal or plastic material. Such power module allows converting a direct current provided by the battery into alternating currents, commonly named “phase currents” , e.g. for controlling a motor. The inverter comprises elements at high voltage levels and should therefore be manipulated with caution. When an operator needs to remove a cover plate (not shown) , mounted on the front face 3-1 of the casing 2-1, to access internal components 4-1 of the inverter 1-1, the electronic control unit 20-1 shall be switched off (i.e. shut down) to prevent the operator from being electrocuted. In order to increase the safety of operators, it is known to equip such inverter with an interlock system 10-1 that automatically switches off the electronic control unit 20-1 when the cover plate is removed.

Such interlock system 10-1 is illustrated on Figures 3 and 4. This interlock system 10-1 uses an actuation device that deactivates the electronic control unit 20-1 when the cover plate is removed. To this end, the interlock system 10-1 comprises an interlock switch 10-10 comprising a switch level 10-11 that is configured to abut against the cover plate. The interlock switch 10-10 is mounted on a holder 10-12 using a first screw 10-13 and the holder 10-12 is further mounted inside the casing 2-1 of the inverter 1-1 using a second screw 10-14. The interlock switch 10-10 is connected to the electronic control unit 20-1 via a set of wires 10-15 and a connector 10-16. When the cover plate is fixed on the casing 2-1, the switch level 10-11 is pressed against the cover plate and the electronic control unit 20-1 is activated, i.e. switched on.When the cover plate is removed from the casing 2-1, the switch level 10-11 is released and the electronic control unit 20-1 is deactivated, i.e. switched off.

Such interlock system 10-1 is long and difficult to install, especially as it is necessary to fix the interlock switch 10-10 on the holder 10-12 with the first screw 10-13, then fix the holder 10-12 in the casing 2-1 using the second screw 10-14, and finally connect the interlock switch 10-10 to the electronic control unit 20-1 by plugging the connector 10-16.

Therefore, there is a need for an interlock system that is easy to fix and easy to use in an electrical equipment for the safety of operators.

SUMMARY

The present invention concerns an electrical equipment, in particular for use in an electrical or a hybrid vehicle, said electrical equipment comprising a casing and an electronic control unit, said electronic control unit comprising at least one safety switch configured for switching off the electronic control unit when said at least one safety switch is released and for switching on the electronic control unit when said at least one safety switch is pressed, the electrical equipment further comprising a pin, said pin comprising an elongated body having a proximal end and a distal end, said elongated body being configured so that in a position, called closed position, said distal end abuts against an element of the casing and said proximal end abuts against the at least one safety switch for switching the electronic control unit on.

The pin safety mechanism is simple, reliable and efficient. Moreover, the use of a pin to activate and deactivate the at least one safety switch makes the electrical equipment low-cost, low-mass, resistant, easy to mount and easy to use in order to prevent premature or inadvertent contact of an operator with high voltage levels of the electrical equipment, especially one on a vehicle.

In an embodiment, the electrical equipment further comprises a busbar, the electronic control unit and said busbar being mounted one above the other in said casing, the pin being configured to traverse the busbar so that, in the closed position, its distal end abuts against an element of the casing. Using the busbar is thus an easy way to hold the pin while reducing size and cost of the electrical equipment.

Advantageously, the elongated body of the pin is a U-shaped elongated body. Such shape is easy to make and easy to manipulate when mounting the electrical equipment.

According to an embodiment, the U-shaped elongated body comprises two legs extending in parallel. The space between the two legs define a gap that may be used to receive a stopper mounted on the busbar, blocking therefore the translation movement of the pin relatively to the busbar in a first direction.

In a preferred embodiment, each leg comprises a snap fit shoulder for blocking the pin relatively to the busbar, in particular in a second direction, opposite to the first direction.

Advantageously, an opening is formed in each leg, next to the snap fit shoulder, to provide flexibility to the leg and allows inserting the pin in the busbar until said pin reaches a blocked position.

In a preferred embodiment, the pin is a one-piece element (i.e. a single element) , e.g. molded in the same material. The pin is thus easy to make and easy to install, preventing the use of a holder or screws.

Advantageously, the pin is made of a plastic material, e.g. a polybutylenterephtalat material (for example PBT-GF30) . Such material makes it easy to manufacture the pin while being both low-cost and highly friction resistant.

According to an embodiment, the busbar comprises a compartment for receiving the pin.

In an embodiment, the compartment has a rectangular section.

The compartment is configured to retain the pin in a blocked position, which prevents the use of a specific holder or screws.

In an embodiment, the compartment comprises two snap fit hooks for blocking the snap fit shoulders of the pin.

Advantageously, the compartment comprises a stopper for holding the pin relatively to the busbar.

Advantageously, the busbar is made of a plastic material, e.g. a polybutylenterephtalat material (for example PBT-GF30) , and comprises copper parts for electrical connections.

According to an embodiment, the at least one safety switch comprises a contactor mounted on a terminal (e.g. a button) .

In a preferred embodiment, the electronic control unit comprises two safety switches.

Advantageously, the at least one safety switch is a wave soldering safety switch, which is cheap and simple.

In an embodiment, the electronic control unit comprises a circuit board, the at least one safety switch being mounted on said circuit board.

The electronic control unit may further comprise a plate, the circuit board being fixed to said plate and said plate being fixed to the casing of the electrical equipment.

In an embodiment, the casing comprises a cover plate, the distal end of the pin abutting against said cover plate.

The invention also relates to a method of assembling an electrical equipment, in particular for use in an electrical or a hybrid vehicle, said electrical equipment comprising a casing, an electronic control unit, a busbar and a pin, said electronic control unit comprising at least one safety switch configured for switching off the electronic control unit when said at least one safety switch is released and for switching on the electronic control unit when said at least one safety switch is pressed, said busbar comprising a compartment for receiving said pin, said pin comprising an elongated body having a proximal end and a distal end, said method comprising the steps of inserting the pin into the compartment of the busbar until the pin traverses said compartment and becomes blocked into said compartment, placing the assembly comprising the busbar and the inserted pin in the casing, positioning the electronic control unit on the busbar and the pin so that the said pin abuts against the at least one safety switch, and fixing the electronic control unit to the casing in order to maintain the at least one safety switch in a pressed position.

The invention also concerns an electrical or a hybrid vehicle comprising an inverter as previously described.

The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features will be apparent from the description and drawings, and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings:

- Figure 1 (previously described) represents a perspective partial view of an inverter according to the prior art；

- Figure 2 (previously described) represents a bottom view of the inverter of Figure 1；

- Figure 3 (previously described) represents a perspective view of the interlock system of the inverter of Figures 1 and 2；

- Figure 4 (previously described) represents another perspective view of the interlock system of the inverter of Figures 1 and 2；

- Figure 5 represents a perspective partial view of an inverter according to the invention；

- Figure 6 represents another perspective partial view of the inverter of Figure 5；

- Figure 7 represents a split view of the inverter of Figure 5；

- Figure 8 represents a split view of a busbar, a pin and an electronic control unit of the inverter of Figure 5；

- Figure 9 represents a perspective bottom view of the electronic control unit of the inverter of Figure 5；

- Figure 10 represents a perspective top view of the electronic control unit of the inverter of Figure 5；

- Figure 11 represents a detailed view of Figure 9 showing two safety switches；

- Figure 12 represents a bottom view of the busbar of the inverter of Figure 5；

- Figure 13 represents a perspective view of the busbar and the pin of the inverter of Figure 5；

- Figure 14 represents another perspective view of the busbar and the pin of the inverter of Figure 5；

- Figure 15 represents a perspective view of the pin of the inverter of Figure 5；

- Figure 16 represents a side view of the pin of Figure 15 mounted into a compartment of the busbar of Figures 12 to 14；

- Figure 17 represents a perspective view of an assembly comprising the busbar, the pin and the electronic control unit of the inverter of Figure 5；

- Figure 18 represents another perspective view of the assembly of Figure 17；

- Figure 19 illustrates an embodiment of the method according to the invention.

DETAILED DESCRIPTION

An embodiment of electrical equipment according to the invention will now be described in reference to Figures 5 to 18. In this example, the electrical equipment is an inverter for use in an electrical or hybrid vehicle. However, the invention could apply to any type of electrical equipment, in particular any type of electrical equipment that works at high voltage levels and may present a risk for the safety of an operator, e.g. above 60 Volts.

Figure 5 illustrates an example of an inverter 1-2 for an electrical or hybrid vehicle, such inverter 1-2 allowing to control an electrical motor of the vehicle (not shown) . The inverter 1 comprises a casing 2-2 in which are mounted a plurality of components as described hereafter.

As illustrated on Figures 6 to 8, the inverter 1-2 comprises an electronic control unit 20-2, a busbar 30 and a pin 40. The inverter 1-2 also comprises a power module (not shown) that allows transforming direct current, received from an external power supply such as a battery (not shown) , to alternating current intended for controlling an electrical motor of the vehicle. In this example, the power module is configured for changing a direct current to three alternating (or phase) currents. Alternatively, the power module might be configured for changing a direct current into more or less than three phase currents without limiting the scope of the present invention.

The electronic control unit 20-2 is configured for controlling the power module. In particular, the electronic control unit 20-2 is configured for controlling semiconductor switches encapsulated in the power module.

In this example, as illustrated on Figures 9 and 10, the electronic control unit 20-2 comprises a plate 20A, for example made of metal or plastic, and a circuit board 20B fixed onto said plate 20A. As shown on Figure 6, the plate 20A is mounted in the casing 2-2, for examples using screws, through an open face 3-2 of said casing 2-2. It shall be noted the plate 20A is optional. Therefore, in another embodiment, the electronic control unit 20-2 might only comprise a circuit board 20B which could be directly fixed to the casing 2-2.

In reference to Figures 10 and 11, in order to switch the electronic control unit 20-2 off to prevent an operator being electrocuted when said operator removes the electronic control unit 20-2 to access the internal components of the inverter 1-2, in particular because of the power module using high voltages levels, the electronic control unit 20-2 comprises at least one safety switch 20C, such as e.g. a wave soldering safety switch. In the illustrated example, the electronic control unit 20-2 comprises two safety switches 20C, such redundancy increasing the safety of the electrical equipment.

In this example, each safety switch 20C comprises a contactor 20C1 mounted on a terminal 20C2 acting as a contact switch element (e.g. a button) . The contactors 20C1 are thus configured to move between a released position and a pressed position. In the released position, the contactors 20C1 do not press against the terminals 20C2 and the electronic control unit 20-2 is deactivated, i.e. switched off. In this case, the internal components of the inverter 2-1, in particular the power module, are not at high voltage levels, at least after a discharge time. In the pressed position, the contactors 20C1 do press against the terminals 20C2 and the electronic control unit 20-2 is activated, i.e. switched on. In this case, the power module may be at high voltage levels (particularly when supplied by a battery of the vehicle) .

The electronic control unit 20-2 needs to be activated when said electronic control unit 20-2 is fully mounted into the casing 2-2, i.e. when the safety switches 20C are in their pressed position.

According to the invention, this goal is achieved using the pin 40 and the busbar 30.

In reference to Figures 12 to 14, the busbar 30 comprises a body 30A, three input electrical connectors 30B1 and three output electrical connectors 30B2. The function of the busbar 30 is therefore to connect the three phase connectors of the power module, using three input electrical connectors 30B1, to three output connectors of the inverter 1-2 (not shown) using the output electrical connectors 30B2. Furthermore, the busbar 30 comprises a hollow compartment 30C (or slot) configured for receiving the pin 40. In particular, each input electrical connector 30B1 is integral with a respective output electrical connector 30B2.

In this example, as illustrated on Figure 16, the compartment 30C comprises a first portion 30C1 of a first rectangular internal section and a second portion 30C2 of a second rectangular internal section, bigger than the first rectangular internal section of the first portion 30C1, defining therefore two opposite snap fit hooks 30D.

The compartment 30C further comprises a stopper 30E protruding orthogonally to the snap fit hooks 30D and configured to prevent the pin 40 to go through the compartment 30C and damage a cover plate 50 of the casing 2-1. To this aim, the junction portion between the two legs 40B (described herein below) comes against the stopper 30E.

In the preferred embodiment illustrated on the Figure 15, the pin 40 is a one-piece element constituted of an elongated U-shaped body 40A extending between a proximal end 40A-P and a distal end 40A-D. In a position called “closed position” wherein the electronic control unit 20-2 is mounting into the casing 2-2, the proximal end 40A-P, constituting the base of the U-shape body 40A, is configured for abutting against the contactors 20C1 of the safety switches 20C whereas the distal end 40A-D is configured for abutting against the cover plate 50 of the casing 2-2.

The U-shaped body 40A comprises two legs 40B extending in parallel and defining a space 40B1 in between, said space 40B1 being configured to receive the stopper 30E of the compartment 30C. The free ends of the two legs 40B constitute the distal end 40A-D of the pin 40.

Each leg 40B comprises a snap fit shoulder 40C and an opening 40D. The snap fit shoulder 40C is formed on a an external face of a side portion of said leg 40B in order to block the pin 40 on the snap fit hooks 30D of the compartment 30C.

The opening 40D is formed in a middle portion of said leg 40B next to the corresponding snap fit shoulder 40C in order to provide some flexibility to the side portion of said leg 40B and allow therefore the snap fit shoulder 40C to go pass the snap fit hook 30D when the pin 40 is inserted into the compartment 30C as illustrated on Figure 16.

An exemplary embodiment of the method for assembling the electrical equipment will now be described in reference to Figure 19.

In a step S1, the pin 40 is inserted into the compartment 30C of the busbar 30 until the snap fit shoulders 40C go pass the snap fit hooks 30D, blocking thus the pin 40 in the compartment 30C, as shown on Figure 16.

The snap fit hooks 30D in cooperation with snap fit shoulders 40C prevent the pin 40 from going upward out of the compartment 30C. The stopper 30E cooperates with the junction portion between the two legs 40B in order to prevent the pin 40 from going downward, namely in an opposite direction with respect to the upward direction, and out of the compartment 30C.

In a step S2, the assembly comprising the busbar 30 and the pin 40 is placed in the casing 2-2.

In a step S3, the electronic control unit 20-2 is positioned on the busbar 30 and the proximal end 40A-P of the pin 40 so that the contactors 20C1 of the safety switches 20C abut against said proximal end 40A-P.

In a step S4, the plate 20A of the electronic control unit 20-2 is fixed to the casing 2-2, for example using screws. The fixation of the plate 20A on the casing 2-2 pushes the contactors 20C2 of the safety switches 20C against the proximal end 40A-P of the pin 40, therefore pushing the pin 40, until the pin 40 abuts against the stopper 30E of the compartment 30C. At this point, the contactors 20C1 are not yet pressed against the terminals 20C2 and the legs 40B slightly protrude from the casing 2-2.

In an optional step S5, a protection plate (not shown) may be fixed on the face 3-2 of the casing 2-2 in order to close the inverter 1-2 and protect the control board 20B of the electronic control unit 20-2.

In a step S6, a cover plate 50 of the casing 2-2 is fixed on said casing 2-2, in this example using screws 50A. While said cover plate 50 is being mounted, the two legs 40B of the pin 40, which abut against said cover plate 50, push the pin 40 backward towards the safety switches 20C, pushing the contactors 20C1 toward the terminals 20C2. When the fixing of the cover plate 50 is achieved, the contactors 20C1 are pressed against the terminals 20C2 so that the safety switches 20C have reached their pressed position. The electrical equipment is then in a position called “closed position” .

In an alternative embodiment, the cover plate 50 could be a wall of the casing (i.e. formed in the same material as the rest of the casing) . In this case, the assembly comprising the busbar 30 and the pin 40 is first placed in the casing 2-2, the two legs 40B of the pin 40 first abutting thus against thecasing wall. Then, the plate 20A of the electronic control unit 20-2 is fixed to the casing 2-2, pushing the contactors 20C1 against the pin 40 until said contactors 20C1 press against the terminals 20C2, reaching therefore the closed position.

It shall be noted that other internal components of the inverter 1-2 might have been mounted inside the casing 2-2 prior to any of steps S1, S2 or S3.

Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure.

More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.

Claims

An electrical equipment (1-2) , in particular for use in an electrical or a hybrid vehicle, said electrical equipment (1-2) comprising a casing (2-2) and an electronic control unit (20-2) , said electronic control unit (20-2) comprising at least one safety switch (20C) configured for switching off the electronic control unit (20-2) when said at least one safety switch (20C) is released and for switching on the electronic control unit (20-2) when said at least one safety switch (20C) is pressed, the electrical equipment (1-2) further comprising a pin (40) , said pin (40) comprising an elongated body (40A) having a proximal end (40A-P) and a distal end (40A-D) , said elongated body (40A) being configured so that in a position, called closed position, said distal end (40A-D) abuts against an element (50) of the casing (2-2) and said proximal end (40A-P) abuts against the at least one safety switch (20C) for switching the electronic control unit (20-2) on.
An electrical equipment (1-2) according to claim 1, further comprising a busbar (30) , the electronic control unit (20-2) and said busbar (30) being mounted one above the other in said casing (1-2) , the pin (40) being configured to traverse the busbar (30) so that, in the closed position, its distal end (40A-D) abuts against an element (50) of the casing (2-2) .
An electrical equipment (1-2) according to any of the preceding claims, wherein the elongated body (40A) of the pin (40) is a U-shaped elongated body (40A) .
An electrical equipment (1-2) according to claim 3, wherein the U-shaped elongated body (40A) comprises two legs (40B) extending in parallel.
An electrical equipment (1-2) according to claim 4, wherein each leg (40B) comprises a snap fit shoulder (40C) .
An electrical equipment (1-2) according to claim 5, wherein each leg (40B) comprises an opening (40D) .
An electrical equipment (1-2) according to any of the preceding claims, wherein the pin (40) is a one-piece element.
An electrical equipment (1-2) according to any of the preceding claims, wherein the busbar (30) comprises a compartment (30C) for receiving the pin (40) .
An electrical equipment (1-2) according to claim 8, wherein the compartment (30C) has a rectangular section.
An electrical equipment (1-2) according to any of claims 8 or 9, wherein the compartment (30C) comprises two snap fit hooks (30D) .
An electrical equipment (1-2) according to any of claims 8 to 10, wherein the compartment (30C) comprises a stopper (30E) .
An electrical equipment (1-2) according to any of the preceding claims, wherein the at least one safety switch comprises a contactor (20C1) mounted on a terminal (20C2) .
An electrical equipment (1-2) according to any of the preceding claims, wherein the at least one safety switch (20C) is a wave soldering safety switch.
An electrical equipment (1-2) according to any of the preceding claims, wherein the casing (2-2) comprises a cover plate (50) , the distal end (40A-D) of the pin (40) abutting against said cover plate (40A-D) .
A method of assembling an electrical equipment (1-2) , in particular for use in an electrical or a hybrid vehicle, said electrical equipment (1-2) comprising a casing (2-2) , an electronic control unit (20-2) , a busbar (30) and a pin (40) , said electronic control unit (20-2) comprising at least one safety switch (20C) configured for switching off the electronic control unit (20-2) when said at least one safety switch (20C) is released and for switching on the electronic control unit (20-2) when said at least one safety switch (20C) is pressed, said busbar (30) comprising a compartment (30C) for receiving said pin (40) , said pin (40) comprising an elongated body (40A) having a proximal end (40A-P) and a distal end (40A-D) , said method comprising the steps of:

-inserting (S2) the pin (40) into the compartment (30C) of the busbar (30) until the pin (40) traverses said compartment (30C) and becomes blocked into said compartment (30C) ,

-placing (S3) the assembly comprising the busbar (30) and the inserted pin (40) in the casing (2-2) ,

-positioning (S4) the electronic control unit (20-2) on the busbar (30) and the pin (40) so that the said pin (40) abuts against the at least one safety switch (20C) ,

-fixing (S5) the electronic control unit (20-2) to the casing (2-2) in order to maintain the at least one safety switch (20C) in a pressed position.