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DE-102024132576-A1 - Power distribution unit

DE102024132576A1DE 102024132576 A1DE102024132576 A1DE 102024132576A1DE-102024132576-A1

Abstract

Power distribution unit (1) with at least two electrical connection areas, namely at least one first electrical connection area (2, 2') and at least one second electrical connection area (3, 3'), wherein the first electrical connection area (2, 2') has at least one fixed first electrical contact element (4a-4g) and the second electrical connection area (3, 3') has at least one fixed second electrical contact element (5a-5g), wherein the first electrical contact element (4a-4g) and the second electrical contact element (5a-5g) are electrically connectable and disconnectable via at least one movable third electrical contact element (6a-6g), wherein the third electrical contact element (6a-6g) is biased into a switching position (A, B) via at least one elastic element (7) and can be actuated into at least one other switching position (A, B) via an actuator unit (8), wherein the actuator unit (8) has at least one actuator (9) and at least one a switching shaft (10) which is movable via the actuator and, depending on the actuated switching position (A, B), leaves the third electrical contact element (6a-6g) in the preloaded switching position (A, B) or moves it against the spring force of the elastic element (7) into at least one other switching position (A, B), wherein the switching shaft (10) drives a switching wheel (32) via a drive wheel (30) and the combination of switching wheel (32)-drive wheel (30) represents a stepping mechanism (41).

Inventors

  • Michael Schneider
  • Andreas Kurz
  • Marcel Bresk

Assignees

  • Magna powertrain gmbh & co kg

Dates

Publication Date
20260513
Application Date
20241108

Claims (5)

  1. Power distribution unit (1) with at least two electrical connection areas, namely at least one first electrical connection area (2, 2') and at least one second electrical connection area (3, 3'), wherein the first electrical connection area (2, 2') has at least one fixed first electrical contact element (4a-4g) and the second electrical connection area (3, 3') has at least one fixed second electrical contact element (5a-5g), wherein the first electrical contact element (4a-4g) and the second electrical contact element (5a-5g) are electrically connectable and disconnectable via at least one movable third electrical contact element (6a-6g), wherein the third electrical contact element (6a-6g) is biased into a switching position (A, B) via at least one elastic element (7) and can be actuated into at least one other switching position (A, B) via an actuator unit (8), wherein the actuator unit (8) has at least one actuator (9) and at least one a mechanical interface to the switching shaft (10) which is movable via the actuator and, depending on the actuated switching position (A, B), leaves the third electrical contact element (6a-6g) in the preloaded switching position (A, B) or moves it against the spring force of the elastic element (7) into at least one other switching position (A, B), characterized in that the actuator unit (8) drives a switching wheel (32) via a drive wheel (30) and that the combination switching wheel (32)-drive wheel (30) represents a stepping gear (46).
  2. Power distribution unit (1) according Claim 1 , characterized in that the switching wheel (32) has an outer contour with concave wing surfaces (36) between the grooves (33).
  3. Power distribution unit (1) according Claim 2 , characterized in that the groove distribution extends radially towards the pivot point of the switching wheel (32) at equal degree intervals.
  4. Power distribution unit (1) according to one of the preceding Claims 2 or 3 , characterized in that the drive wheel (30) has a pin (31) for engaging in the grooves of the switching wheel and a convex contour (35) for supporting the concave wing surfaces (36) of the switching wheel.
  5. Power distribution unit (1) according to one of the preceding claims, characterized in that the cams of the switching shaft (10) press the third electrical contact element (6a-6g) against the spring force of the elastic element (7).

Description

The invention relates to a power distribution unit with at least two electrical connection areas, namely at least a first electrical connection area and at least a second electrical connection area, wherein the first electrical connection area has at least one fixed first electrical contact element and the second electrical connection area has at least one fixed second electrical contact element, wherein the first electrical contact element and the second electrical contact element are electrically connectable and disconnectable via at least one movable third electrical contact element, wherein the third electrical contact element is biased into a switching position via at least one elastic element and can be actuated into at least one other switching position via an actuator unit, wherein the actuator unit has at least one actuator and at least one switching shaft which is movable via the actuator and, depending on the actuated state, either leaves the third electrical contact element in the biased switching position or moves it against the spring force of the elastic element into at least one other switching position. State of the art Power distribution units for motor vehicles, especially for hybrid or electric vehicles, have, in addition to fuse units and voltage and current measuring systems, switching arrangements that prevent or enable the flow of electricity through an electrical circuit of the vehicle. These switching arrangements typically consist of at least three relays – depending on the design, at least two high-current relays and one pre-charging relay are used. Additional relays may also be included for switching drive units on and off, DC charging contacts, battery bank switching, and other functions. The relays used each consist of a contact and an actuator, which are controlled by corresponding output stages of a control unit and monitored via specific circuits. The use of multiple individual relays and actuators results not only in high costs, but also in increased installation space requirements and weight. Furthermore, the relays themselves typically have two high-current connections that can only be passively cooled via the connected busbars. This negatively impacts the installation space and weight of the contact technology. The requirements for current carrying capacity and opening/closing speed also necessitate adjustments to the actuators. This negatively affects the overall weight, volume, and energy efficiency. Additionally, complex control and monitoring systems are required for each individual relay to detect and prevent malfunctions. The sum of all these disadvantages necessitates an improved switching arrangement suitable for use in a power distribution unit of a battery-electric vehicle. The high-voltage relays used are generally identical in construction and each consists of a contact and an actuator, which are controlled by corresponding output stages of a control unit and monitored via specific circuits. Each of these relays has the necessary technology integrated to interrupt the current flow even under load. From the as yet unpublished DE 10 2023 209 219 A switching arrangement is known. This arrangement features a camshaft or crankshaft as its central actuating element for operating the contacts. Depending on the number of switching positions, various switching positions of the actuating shaft result. Since this is a spring-loaded unit, it is important that the contacts and the shaft remain in the defined switching position. The springs are subject to external environmental influences such as vibrations and acceleration peaks, so a mechatronic actuation concept for the camshaft or crankshaft is necessary to ensure that the switching position of the individual switches remains reliably engaged or disengaged. Due to the requirement to switch under load in certain situations, the switch contacts must open or close within a defined time; otherwise, excessive arcing will occur at the contacts. This arcing leads to wear on the components. It is an object of the invention to provide an improved electromechanical switching arrangement wherein the switches are connected safely and simply. Description of the invention The problem is solved with a power distribution unit having at least two electrical connection areas, namely at least a first electrical connection area and at least a second electrical connection area, wherein the first electrical connection area has a minimum length of... at least one fixed first electrical contact element and the second electrical connection area has at least one fixed second electrical contact element, wherein the first electrical contact element and the second electrical contact element are electrically connectable and disconnectable via at least one movable third electrical contact element, wherein the third electrical contact element is biased into a switching position via at least one elastic element and can be actuated into at least one o