COUPLING DEVICE
20220311186 · 2022-09-29
Assignee
Inventors
Cpc classification
H01R13/703
ELECTRICITY
H01R13/6205
ELECTRICITY
H01M10/48
ELECTRICITY
International classification
H01R13/62
ELECTRICITY
Abstract
A coupling device (1) is provided with a first connection module (12) and a second connection module (14) releasably connectable to the first connection module (12). The first connection module (10) and the second connection module (14) form a connector (10). The coupling device (1) is adapted to apply a coupling force that creates a connection between the first connection module (12) and the second connection module (14), and to apply a decoupling force that releases the connection. The decoupling force and the coupling force are applied by the first connection module (12) to the second connection module (14), and the decoupling force counteracts the coupling force. The coupling force is provided by a pneumatic, hydraulic, electric, or electromagnetic actuator (20) provided on the first connection module (12). The decoupling force is provided by a mechanical, electrostatic, or magnetic storage device (24) capable of receiving, storing, and releasing a portion of the energy generated by the coupling force. The coupling force is provided by a coupling mechanism, and the decoupling force is provided by a decoupling mechanism. The decoupling mechanism forms a unit with the coupling mechanism.
Claims
1. A coupling device (1) comprising: a first connection module (12), and a second connection module (14) releasably connectable to the first connection module (12); wherein the first connection module (10) and the second connection module (14) form a connector (10), wherein the coupling device (1) is adapted to: apply a coupling force that creates a connection between the first connection module (12) and the second connection module (14), and apply a decoupling force that releases the connection; wherein the decoupling force and the coupling force are applied by the first connection module (12) to the second connection module (14), the decoupling force counteracts the coupling force, the coupling force is provided by a pneumatic, hydraulic, electric, or electromagnetic actuator (20) provided on the first connection module (12), the decoupling force is provided by a mechanical, electrostatic, or magnetic storage device (24) capable of receiving, storing, and releasing a portion of the energy generated by the coupling force, the coupling force is provided by a coupling mechanism, the decoupling force is provided by a decoupling mechanism, and the decoupling mechanism forms a unit with the coupling mechanism.
2. The coupling device (1) according to claim 1, wherein the coupling force is provided by an operating mechanism that is different from the operating mechanism of the decoupling force.
3. The coupling device (1) according to claim 2, wherein the second connection module (14) has an engagement portion (16), the first connection module (12) has an engagement unit (22) cooperating with the engagement portion (16) such that the engagement unit (22) is movable between the following positions: an alignment position (AP) in which the second connection module (14) is aligned with the first connection module (12) and is removable from the first connection module (12), and a locking position (VP) in which the second connection module (14) is aligned with the first connection module (12) and is prevented from being removed from the first connection module (12).
4. The coupling device (1) according to claim 3, wherein there is no connection for power transmission in the alignment position (AP) and in the locking position (VP).
5. The coupling device (1) according to claim 4, wherein the engagement unit (22) is further movable to a coupling position (KP) in which the engagement unit (22) is engaged with the engagement portion (16) and the coupling force is applied to the second connection module (14) by the engagement to move the second connection module (14) to a coupled position and hold it there so that there is a connection for power transmission.
6. The coupling device (1) according to claim 5, wherein the actuator (20) is an electric or pressure operated swing clamp cylinder comprising a rod having at its distal end the engagement unit (22), and the engagement unit (22) is rotatable by the swing clamp cylinder between the alignment position (AP) and the locking position (VP) and is axially displaceable between the locking position (VP) and the coupling position (KP).
7. The coupling device (1) according to claim 6, wherein the storage device (24) is a spring which is relaxed or preloaded in the alignment position (AP) and tensioned in the coupling position (KP).
8. The coupling device (1) according to claim 6, wherein the storage device (24) and the actuator (20) are adapted so that the energy output of the storage device causes a movement of the engagement unit (22) from the coupling position (KP) via the locking position (VP) to the alignment position (AP).
9. The coupling device (1) according to claim 1, further comprising a guiding device (30) for aligning the second connection module (14) with the first connection module (12).
10. The coupling device (1) according to claim 9, wherein the guiding device (30) comprises: a support plate (34) provided on the first connection module (12); and a support projection (32) provided on the second connection module (14); wherein the support projection (32) rests on the support plate (34) in the alignment position (AP) to align the second connection module (14) with the first connection module (12).
11. The coupling device (1) according to claim 10, wherein the guiding device (30) comprises: a guiding hole (38) provided on the first connection module (12); and a guiding pin (36) provided on the second connection module (14); wherein the guiding hole (38) and the guiding pin (36) are adapted to guide the second connection module (14) between the locking position (VP) and the coupling position (KP) relative to the first connection module (12) so that the aligned connection modules (12, 14) are movable in the coupling direction.
12. The coupling device (1) according to claim 1, wherein the first connection module (12) and the second connection module (14) are adapted to transmit at least one of an electrical power, an electrical signal and a pressurized fluid.
13. A coupling system (50) comprising a coupling device (1) according to claim 12, an emergency stop device (54) adapted to interrupt the provision of power to the first connection module (12) and to interrupt the pressure supply or energy supply to the actuator (20) when actuated.
14. The coupling system (50) according to claim 13, further comprising: a first switch (56) that switches the provision of power to the first connection module (12); and a second switch (58) that switches the pressure supply or energy supply to the actuator (20).
15. The coupling system (50) according to claim 14, wherein the coupling device (1) is provided inside a test rig space (52), the first switch (56) is provided outside the test rig space (52), and the second switch (58) is provided so as to be operable to turn off the pressure supply or energy supply from outside the test rig space (52) and operable to turn on the pressure supply or energy supply from inside the test rig space (52).
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION OF THE EMBODIMENT
[0068] In
[0069] Directional indications in the following description are determined with reference to a normal direction of the wall to which the coupling device 1 is attached, and to a direction of gravity, A left-right direction is the direction perpendicular to both the normal direction and the gravity direction. An object or geometry element that is far from the wall in the normal direction is referred to as “front”; a geometry element close to the wall is referred to as “rear”, “Top” and “bottom” refer to the direction of gravity. The terms “left” and “right” are determined when viewed from the front (that is, looking at the wall viewed from inside the test rig space along the normal direction). For clarity, directional arrows are shown in
[0070] Connection Modules
[0071] The coupling device 1 shown in
[0072] In the embodiment, the first connection module 12 has a socket module that provides power (electrical power) for the test operation. The socket module is substantially a metal plate with one or more connection sockets provided thereon. The connection sockets are preferably modularly interchangeable so that they can selectively provide and transmit power or pressurized fluids depending on the requirements of the test object 60 or the test to be performed. The first connection module 12 further has a frame 13 attached to the wall of the test rig space 52. In the embodiment, the frame 13 is formed as two parallel plates with a plurality of spacers, one of which is attached to the wall and the other of which is spaced from the wall at a certain distance. Two actuators 20 described later are arranged between the plates of the frame 13. In the embodiment, the frame 13 further has two symmetrically arranged protrusions 15 which support the socket module from below. The socket module can be removed from the frame 13 or the protrusions 15 and replaced. The socket module is further connected by connecting means 17, e.g. cables or hoses, to the test rig space 52 and corresponding devices for power provision and/or signal transmission. In the embodiment, four cables are provided as connecting means 17.
[0073] In the embodiment, the second connection module 14 has a substantially square main body with a plug module having a matching plug for each socket of the socket module, which receives the power provided by the first connection module 12 and conducts it through four cables 18 to the test object 60. If the first connection module 12 is configured to transmit signals or pressurized fluids as an alternative to or in addition to transmitting power, the associated plugs and cables of the second connection module 14 are adapted accordingly to enable the transmission to or from the test object 60. The second connection module 14 has at least one engagement portion 16 and at least one support projection 32, In the embodiment, the engagement portion 16 and the support projection 32 are elongated ribs. An engagement portion 16 and a support projection 32 are disposed on the left and right sides of the main body of the second connection module 14, respectively, the engagement portion 16 extending in the direction of gravity and the support projection 32 extending in the normal direction. These elements will be described in more detail later.
[0074] Actuator and Engagement Unit
[0075] In the embodiment, two actuators 20 are provided symmetrically about the center of the first connection module 12, Therefore, only the left actuator 20 is described below; the right actuator 20 has an analogous configuration.
[0076] In the embodiment, the actuator 20 is a pneumatic swing clamp cylinder whose main body is arranged between the two plates of the frame 13 of the first connection module 12. A movable rod projects forward from the main body of the actuator 20, and an engagement unit 22 is attached to the end of the rod. The engagement unit 22 is a cylinder having two concentric circular plates spaced apart from each other. The front circular plate has a recess in the form of a chord. The rear circular plate does not have the recess. The rod and thus the engagement unit 22 are axially displaceable (i.e., in the coupling direction) and are also rotatable about the longitudinal axis of the rod. The actuator 20 and the engagement unit 22 form a coupling mechanism.
[0077] An axial end position of the engagement unit 22 corresponds to the extended position of the actuator 20. In or near this end position, the engagement unit 22 is rotatable. In the embodiment, in the end position and without actuation of the actuator 20, the engagement unit 22 is rotated such that the chord of the front circular plate extends in the direction of gravity. This position of the engagement unit 22 is referred to as the alignment position AP. In the alignment position AP, the recesses of the front circular plates of the right and left engagement units 22 face each other, the distance between the chords being slightly greater than the distance between the outer edges of the two engagement portions 16. Thus, the shape of each recess follows the shape of the associated engagement portion 16 with an offset.
[0078] An initial actuation of the actuator 20 results in the engagement unit 22 being rotated by 90°, wherein an additional axial movement is possible. This position of the engagement unit 22 is referred to as the locking position VP. A further actuation of the actuator 20 results in the engagement unit 22 being axially displaced to another end position, the rotation of the locking position VP being maintained or retained. This position of the engagement unit 22 is referred to as the coupling position KP. The effects of the various positions AP, VP, KP will be described later with reference to the coupling process.
[0079] Storage Device
[0080] A spring 24 designed as a compression spring serving as a storage device or energy storage device is provided concentrically around the rod of the actuator 20, The spring 24 abuts the rear circular plate from behind and biases the engagement unit 22 forwards. Accordingly, the spring 24 urges the engagement unit 22 toward the alignment position AP. Thus, the spring 24 as a storage device is also a decoupling mechanism that forms a unit with the coupling mechanism (the actuator 20 and the engagement unit 22) in the embodiment. However, it is also possible to configure the decoupling mechanism (the storage device) different to a spring and to separate it spatially from the coupling mechanism, for example, by providing two magnets centrally in the connection modules 12, 14 and having their same poles facing each other so that the magnets and thus the connection modules 12, 14 repel each other.
[0081] Guiding Device
[0082] The coupling device 1 further has a guiding device 30. The guiding device 30 in the embodiment includes the two support projections 32 described above paired with two support plates 34 (
[0083] The support plates 34 each rest on the protrusions 15 and provide a first surface on which the opposing support projection 32 can rest in the direction of gravity. The first surface is an upper surface in
[0084] The guiding pins 36 are provided on the plug module of the second connection module 14 and can project with a slight clearance into the guiding holes 38 provided in the socket module opposite the guiding pins 36. In the embodiment, the length of the guiding pins 36 is shorter than the axial distance between the rear circular plate of the engagement unit 22 and the front end of the support plate 34. Thus, there is a position of the second connection module 14 in which the second connection module 14 rests on the support plate 34 without the guiding pins 36 and the guiding holes 38 engaging with each other. This allows alignment using the support plate 34 prior to more precise alignment with the guiding pin 36. In addition, the guiding pins 36 have different cross sections. The upper guiding pin 36 in
[0085] Coupling Process
[0086] With the structure described above, an example of a coupling process results, which is described below with reference to
[0087] Initially, the test object 60 is located in the test rig space 52 without being connected. The test object 60 has cables 18 connecting it to the second connection module 14, which has no contact with the first connection module 12. The engagement unit 22 of the first connection module 12 is in the alignment position AP. As an example, this state is shown in
[0088] In an initial state for the coupling, the second connection module 14 is provisionally aligned with the first connection module 12 by an assembler, namely to the correct height (
[0089] In a first step, the second connection module 14 is placed on the support plates 34 of the first connection module 12 and displaced along the coupling direction. The support projections 32 and the main body of the second connection module 14 cooperate with the support plates 34 and gravity to guide the second connection module 14 in the coupling direction. The front circular plate of the engagement unit 22 has the recess following the shape of the engagement portion 16 with an offset to allow the second connection module 14 to be displaced along the coupling direction starting from the initial state. Thus, the engagement portion 16 of the second connection module 14 passes through the recess before coming into abutment with the rear circular plate of the engagement unit 22. At the end of the movement, the engagement portions 16 of the second connection module 14 abut the rear circular plates of the engagement unit 22. This corresponds to the aligned state in which the second connection module 14 is aligned with the first connection module 12 and is removable from the first connection module 12. The lengths of the plugs of the second connection module 14 are selected such that, in the aligned state, the plugs do not reach the socket module and thus no power transmission can occur. Leading contacts coming into contact before the power transmission is initiated can also be used, for example, for shielding/grounding.
[0090] In a next step, an initial actuation of the actuator 20 takes place. The initial actuation results in a rotation of the engagement unit 22, so that the recess of the front circular plate is rotated by 90° (see
[0091] In a next step, a continued actuation of the actuator 20 takes place. The continued actuation results in an axial displacement of the engagement unit 22 in the coupling direction and a compression of the spring 24. During the axial displacement of the engagement unit 22, the front circular plate thereby comes into abutment with the front side of the engagement portion 16 of the second connection module 14. As a result, the second connection module 14 is urged by the engagement unit 22 with a coupling force in the coupling direction and is guided by the support plates 34. After part of the distance to be axially traveled by the second connection module 14, the guiding pins 36 also project into the guiding holes 38 to align the plug module of the second connection module 14 even more precisely with the socket module of the first connection module 12 and to improve the guiding accuracy. From about half of the distance to be axially traveled, the plugs of the plug module come into contact with the sockets of the socket module. At the end of the displacement, the engagement unit 22 assumes the coupling position KP, the second connection module 14 has assumed a corresponding coupled position, the plugs and the sockets are in contact, and a power transmission is possible. This corresponds to a coupled state and is shown in
[0092] As long as coupling is desired, the actuation of the actuator 20 is maintained in the coupled state. Thus, the coupling force is maintained and the engagement unit 22 is held in the coupling position KP so that the second connection module 14 remains in the coupled state,
[0093] Decoupling Process
[0094] As the spring 24 has been compressed during the continued actuation of the actuator 20, the spring 24 has stored a part of the energy provided by the actuator 20 by means of the coupling force in the form of potential energy. Accordingly, the spring 24 applies a decoupling force to the engagement unit 22 and urges it forward, that is, from the coupling position KP toward the alignment position AP. In addition, the spring 24 is configured to apply a residual biasing force to the engagement unit 22 in the alignment position AP. This biasing force serves to compensate for sliding friction losses and also accelerates decoupling.
[0095] In order to decouple the second connection module 14 from the first connection module 12, the actuation of the actuator 20 is interrupted by interrupting the pressure supply or electrical energy supply. In the embodiment, the actuator 20 is a pneumatic swing clamp cylinder; therefore, the compressed air supply is interrupted for this purpose.
[0096] After the interruption, the coupling force, which counteracts the decoupling force and was in equilibrium with the decoupling force in the coupling position KP, is eliminated. Accordingly, the decoupling force now urges the second connection module 14 forward and away from the first connection module 12. Because of the axial movement, the engagement unit 22 therefore reaches the locking position VP and is further axially displaced. The structure of the actuator 20 also causes the rotation of the engagement unit 22, so that at the end of the axial movement the engagement unit 22 is in the alignment position AP, Thus, the relaxation of the spring 24 causes the engagement unit 22 to move from the coupling position KP via the locking position VP to the alignment position AP. By separating the decoupling function (transition from the coupled state to a decoupled state, in this case the locked state) from the locking function (transition from the locked state to the aligned state), that is, by a sequential timing of decoupling and locking, an ejection of the second connection module 14 can be prevented.
[0097] Since power transmission is not possible in the alignment position AP and the second connection module 14 is removable from the first connection module 12, the connection modules 12, 14 are thus decoupled,
[0098] Coupling System
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[0100] The coupling system 50 couples the test rig space 52 to the test object 60. The test object 60 is a battery pack comprising a plurality of battery cells for a battery electric vehicle (BEV) or a plug-in hybrid vehicle (PHEV). The test object 60 is mounted on a handcart, which can be used to drive it into the test rig space 52 through a door and to remove it from the test rig space 52 quickly, for example, in an emergency. The test rig space 52 is used to test the test object 60 under real load conditions, more specifically to simulate charging and discharging operations.
[0101] In order to supply electrical power to the test object 60 for these operations, the coupling device 1 is mounted on a wall of the test rig space. The coupling device 1 is connected via cables 17A to a first switch 56 and to a pressure line 17B to a second switch 58. The pressure line 17B provides compressed air to actuate the actuator 20, and the cables 17A provide electrical power to the test object 60, The electrical power is transmitted through the coupling device 1 to cables 18, which conduct it to the test object 60.
[0102] The first switch 56 can activate and deactivate the power supply. The second switch 58 can switch the pressure supply to the actuator 20, and thus control the coupling and decoupling by means of controlling the actuator 20. The first switch 56 and the second switch 58 can be operated independently of each other. Therefore, the operations for coupling/decoupling the connection modules 12, 14 and for providing/interrupting the power transmission are independent of each other.
[0103] The first switch 56 is located outside the test rig space 52, such as in a control room. The second switch 58 has a part 58A disposed outside the test rig space 52 and a part 58B disposed inside the test rig space 52. The part 58A outside the test rig space 52 can only interrupt the pressure supply. The part 58B inside the test rig space 52 can both interrupt and turn on the pressure supply. Accordingly, only an assembler inside the test rig space 52 can couple the connection modules 12, 14 together, while only a supervisor outside the test rig space 52 can turn on the power supply. Thus, the coupling system is configured so that the locked state can be permanently present, but the coupled state can only be brought about when there are no persons in the test rig space, further improving the assembly safety. Further, the part 58B of the second switch 58 is sufficiently far from the coupling device 1 so that the assembler cannot actuate the part 58B of the second switch 58 while touching the second connection module 14. Thus, the assembler must remove his/her hands from the second connection module 14 in order to actuate the part 58B of the second switch 58 and actuate the actuator 20, thereby reducing the risk of injury. The assembler or any supervisory or security personnel, on the other hand, can decouple the connection modules 12, 14 with any of the parts 58A and 58B at any time, allowing for a quick decoupling and removal of the test object 60 from the test rig space 52 in an emergency.
[0104] The two switches 56 and 58 are part of an emergency stop device 54, which is configured such that actuation of the emergency stop device 54 causes both switches 56 and 58 to be interrupted simultaneously. This causes the test rig to shut down while simultaneously decoupling the connector. Individual actuation of each switch 56, 58 also remains independently possible for better control of regular operation and assembly work.
[0105] Modifications
[0106] In the embodiment, two pneumatic swing clamp cylinders, namely one on each of the left and right sides of the connection modules 12, 14, are provided as actuators 20. Other types of actuators are applicable, and their number can be adjusted according to the spatial situation, the force requirement and the available actuation type.
[0107] Although the embodiment has been described with regard to electrical power transmission, the coupling device can alternatively or additionally be used for a pneumatic or hydraulic power transmission. For this purpose, the connection modules 12, 14 are modified by replacing some or all of the cables 17, 18 with hoses and the associated sockets and plugs with hose couplings.
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[0110] A first modification 101 in
[0111] A second modification 201 in
[0112] A third modification 301 in
[0113] In the embodiment, the initial actuation and the continued actuation of the actuator 20 can be performed independently. Thus, the initial actuation and the continued actuation are separate actuations that allow a separation between the locking position and the coupling position. Alternatively, the two actuations can be performed as one continuous actuation so that locking and coupling can be performed as one uninterrupted operation. Accordingly, the locked state becomes a transitional state, and the second connection module 14 is switchable between an aligned state without power transmission and a coupled state with power transmission. Such a structure enables the use of a simple and cost-effective actuator and reduces the complexity of control required.
[0114] The first surfaces of the two support plates 34 in the embodiment are flush, and gravity allows the second connection module 14 to rest and thus holds it in the horizontal plane. Alternatively, a plurality of first surfaces of one or more support plates 34 can guide the second connection module 14 in any plane or along a curved surface.
[0115] The embodiment has been described with reference to a normal direction of the wall to which the coupling device 1 is attached, and the normal direction is also the coupling direction. However, the coupling device need not be attached to a wall, but can be arranged, for example, in a freestanding manner on a rack. In addition, the normal direction and/or the coupling direction can be replaced by any other reference direction in order to also enable oblique coupling of the connection modules, depending on the spatial conditions.
LIST OF REFERENCE SIGNS
[0116] 1 Coupling device [0117] 100 . . . first modification [0118] 200 . . . second modification [0119] 300 . . . third modification [0120] 10 power connector [0121] 12 first connection module [0122] 13 frame [0123] 14 second connection module [0124] 15 protrusion [0125] 16 engagement portion [0126] 17 connecting means [0127] 17A cable [0128] 17B pressure line [0129] 18 cable to test object [0130] 19 transmission parts [0131] 19A electrical transmission part [0132] 19B hydraulic transmission part [0133] 20 actuator [0134] 22 engagement unit [0135] AP alignment position [0136] KP coupling position [0137] VP locking position [0138] 24 storage device [0139] 30 guiding device [0140] 32 support projection [0141] 34 support plate [0142] 36 guiding pin [0143] 38 guiding hole [0144] 50 coupling system [0145] 52 test rig space [0146] 54 emergency stop device [0147] 56 first switch [0148] 58 second switch [0149] 58A outside [0150] 58B inside [0151] test object