Inductive Power Transfer Unit and a Method of Manufacturing an Inductive Power Transfer Unit

Abstract

The invention relates to an electronic unit and a method of manufacturing an electronic unit (1), wherein the unit (1) comprises at least electronic component, wherein the unit (1) comprises at least one housing (2) for the at least one electronic component (4, 5, 6, 7) of the unit (1), wherein the unit (1) comprises at least one auxiliary power supply line (8), wherein the unit (1) further comprises an RCD switch element (12), wherein the at least one auxiliary power supply line (8) is fitted with the RCD switch element (12) and at least one exposed section (19) in such a manner that the RCD switch element (12) triggers when the at least one exposed section (19) of the auxiliary power supply line (8) is exposed to a conductive fluid, wherein the at least one exposed section (19) is arranged in a fluid collection volume of the housing.

Claims

1. An electronic unit comprising: at least one electronic component; at least one housing for the at least one electronic component; at least one auxiliary power supply line; and a residual-current device (RC) switch element, wherein the at least one auxiliary power supply line is fitted with the RCD switch element and at least one exposed section in such a manner that the RCD switch element triggers when the at least one exposed section of the auxiliary power supply line is exposed to a conductive fluid, wherein the at least one exposed section is arranged in a fluid collection volume of the housing, and wherein the unit comprises at least one power electronic component and at least one auxiliary electronic component.

2. The unit according to claim 1, wherein the auxiliary power supply line has an internal section arranged inside the housing and an external section arranged outside the housing, and wherein the external section of the auxiliary power supply line is fitted with the RCD switch element.

3. The unit according to claim 1, wherein the unit further comprises at least one main power supply line, wherein the at least one main power supply line is fitted with a supply line breaking means, wherein the RCD switch element has a trip signal interface, and wherein the trip signal interface is connected to the supply line breaking means.

4. The unit according to claim 1, wherein the unit further comprises at least one evaluation unit, and wherein an interrupted state of the at least one auxiliary power supply line is detectable by the at least one evaluation unit.

5. The unit according to claim 1, wherein the at least one exposed section comprises or is provided by at least one uninsulated section.

6. The unit according to claim 1, wherein the exposed section comprises or is provided by at least one series terminal.

7. The unit according to claim 1, wherein the fluid collection volume is arranged in a bottom section of the housing.

8. The unit according to claim 1, wherein the housing is shaped such that the fluid collection volume is the part of an inner volume of the housing in which a fluid accumulates at first.

9. The unit according to claim 1, wherein the unit further comprises at least one fluid collecting element, wherein the fluid collecting element is designed and/or arranged such that a fluid collected by the fluid collecting element contacts the at least one exposed section or wherein the fluid collecting element is designed and/or arranged such that a residual current occurs if the fluid collecting element has collected a predetermined amount of fluid.

10. (canceled)

11. The unit according to claim 1, wherein the unit is an inductive power transfer unit.

12. A method of manufacturing an electronic unit, the method comprising: providing a housing of the electronic unit, having a fluid collection volume; arranging at least one power electronic component and at least one auxiliary electronic component within the housing; providing at least one auxiliary power supply line having at least one exposed section; arranging the exposed section in the fluid collection volume; providing at least one residual-current device (RCD) switch element; and fitting the at least one RCD switch element to the at least one auxiliary power supply line.

13. The method according to claim 12, wherein at least one main power supply line and at least one supply line breaking means is provided, wherein the at least one main power supply line fitted with the supply line breaking means, and wherein a trip signal interface of the RCD switch element is connected to the supply line breaking means.

14. The method according to claim 12, wherein the exposed section comprises at least one uninsulated section or at least one series terminal.

Description

[0076] The invention will be described with reference to the attached figures. The figures show:

[0077] FIG. 1: A schematic block diagram of an inductive power transfer unit according to the invention,

[0078] FIG. 2: A schematic block diagram of an inductive power transfer unit according to another embodiment of the invention,

[0079] FIG. 3: A schematic block diagram of an inductive power transfer unit according to another embodiment of the invention,

[0080] FIG. 4: A schematic block diagram of an inductive power transfer unit according to another embodiment of the invention, and

[0081] FIG. 5: A schematic block diagram of an inductive power transfer unit according to another embodiment of the invention.

[0082] In the following, the same reference numerals denote elements with the same or similar technical features.

[0083] In the following, the invention is exemplarily described for an inductive power transfer unit 1. It is, however, clear to the skilled person that the invention can be applied to any system in which a fluid collecting in an inner volume of a housing comprising electronic components, e.g. to a telecommunication device, an electrically operated pump or a distribution station.

[0084] FIG. 1 shows a schematic block diagram of an inductive power transfer unit 1 according to the invention. The inductive power transfer unit 1 comprises a housing 2. The housing 2 or at least a part thereof is made of electrically conductive material. Further, the housing 2 can be electrically connected to a ground potential. Further, the unit 1 comprises an inverter 4 which provides or comprises power electronic components and multiple auxiliary electronic components, e. g. a control unit 5, a fan 6 and a relay 7. The control unit 5 can e. g. control an operation of the inverter 4. The inverter 4 provides a power electronic component of the unit 1. The inverter 4 and the auxiliary electronic components 5, 6, 7 are arranged in an inner volume 5 of a housing 2.

[0085] In the shown embodiment, in the inductive power transfer unit 1 is a primary unit of a system for inductive power transfer. It is, of course, possible that the inductive power transfer unit 1 provides a secondary unit of said system for inductive power transfer. In this case, the power electronic components arranged in the housing 2 can be different from the shown power electronic components.

[0086] Further, the unit 1 comprises an auxiliary power supply line 8. The auxiliary power supply line can e.g. comprise a neutral line, i.e. a return line 8a, and a phase line, i.e. a feeding line 8b. Via the auxiliary power supply line 8, the auxiliary electronic components 5, 6, 7 are electrically connected to an auxiliary voltage supply 9. The auxiliary voltage supply 9 can e. g. supply an auxiliary voltage of 230 V as an alternating current voltage.

[0087] Further shown is a main power supply line 10, wherein power input terminals of the inverter 4 are connected to a main power supply unit 11 via the main power supply line 10. Power can be provided to the inverter 4 by AC or DC voltage. In case of an AC power supply, the inverter 4 can provide a converter.

[0088] Both, the auxiliary power supply line 8 and the main power supply line 10 comprise an internal section which is arranged within the inner volume 3 of the housing 2 and an external section, which is arranged outside the housing 2. The housing 2 can comprise inlets for the power supply lines 8, 10.

[0089] Further, the unit 1 comprises a RCD 12. The auxiliary power supply line 8 is fitted with the RCD 12. This means that the auxiliary electronic components 5, 6, 7 are connected to the auxiliary power supply unit 12 via the RCD 12. In FIG. 1, the RCD 12 is shown in an open state. In this open state, the auxiliary power supply line 8 is interrupted. Thus, no auxiliary voltage and power is supplied to the auxiliary electronic components 5, 6, 7. In an error-free operation, the RCD 12 can adopt a closed state in which the auxiliary electronic 5, 6, 7 are connected to auxiliary power supply unit 9 and power is supplied to said auxiliary electronic components 5, 6, 7 via the RCD.

[0090] Schematically indicated is one exposed section 19 of the auxiliary power supply line 8, in particular of the feeding line 8b. The exposed section 19 can e.g. be provided by an uninsulated section of the feeding line 8b and/or by a series terminal.

[0091] Further shown is that the exposed section 19 is arranged in a bottom area or bottom volume of the housing 2, in particular below the inverter 4 and the auxiliary electronic components 5, 6, 7 with respect to the vertical direction z. The bottom area or bottom volume provides a fluid collection volume of the housing 2. Fluid, e.g. water, which collects in the inner volume 3, e.g. ingressing water or condensing water, will first collect in said fluid collection volume.

[0092] In other words, the exposed section 19 is arranged in between the inverter 4 and the bottom side of the housing 2 or a carrier element 17 in an installed state of the housing 2. It is, for instance, possible, that a series terminal is mounted to a bottom plate of the housing 2, wherein the series terminal is also arranged in the inner volume 3 in which the inverter 4 and the auxiliary electronic components 5, 6, 7 are arranged.

[0093] The RCD 12 can change from the closed state to the open state if a residual or failure current occurs. In particular, the RCD 12 can adopt the closed state as long as the currents in a return line 8a and a feeding line 8b are equal. If a residual current occurs, the difference between said currents is greater than zero or greater than a predetermined threshold value, e.g. greater than 30 mA. In this case, the RCD 12 can adopt the open state.

[0094] Such a residual current can e. g. occur if fluid penetrates or enters into the inner volume 3 of the housing 2 and/or collects in the inner volume 3 and contacts the auxiliary electronic components 5, 6, 7 or sections of the auxiliary power supply line 8, in particular the exposed sections 19. In this case, the residual current can flow between the exposed section 19 and the housing 2.

[0095] The RCD 12 comprises a trip signal interface 13. Via the trip signal interface 13 which can e.g. be provided by an auxiliary contact element of the RCD 12, the RCD 12 is connected to a circuit breaker switch 14 which is fitted to the main power supply line 10. The circuit breaker switch 14 has also a trip signal interface 15 by which the circuit breaker 14 is connected to the RCD 12 by a signal connection. If the RCD 12 detects a residual current, a trip signal can be generated and transmitted from the RCD 12 to the circuit breaker 14. Upon reception of the trip signal, the circuit breaker switch 14 can adopt an open state in which the main power supply line 10 is interrupted and no power is supplied to inverter 4. In an error-free state, the circuit breaker switch 14 can adopt a closed state in which power is supplied to the inverter 4 by the main power supply unit 11.

[0096] Further shown is a primary winding structure 16 which is connected to AC output terminals of the inverter 4. The primary winding structure 16 is arranged outside the housing 2. It is, however, also possible to arrange the primary winding structure 16 within the housing 2.

[0097] Further shown is that the housing 2 can be arranged on a carrier element 17, e.g. a rack or a ground surface. Not shown are absorber elements, e.g. made of rubber, which absorb or damp mechanical movements, e.g. vibrations, of the housing 2. Further, the housing can be electrically connected to the ground potential via the carrier element 17.

[0098] Further indicated is a vertical direction z wherein the vertical direction can be oriented parallel to a direction of a gravitational force.

[0099] FIG. 2 shows a schematic block diagram of an inductive power transfer unit 1 according to another embodiment of the invention. In contrast to the embodiment shown in FIG. 1, FIG. 2 shows a more detailed arrangement of the auxiliary power supply line 8, in particular of an internal section of the auxiliary power supply line 8. Schematically indicated are two exposed sections 19 of the return line 8a and two exposed sections of the feeding line 8b of the auxiliary power supply line 8. Again, these exposed sections 19 can be provided by uninsulated sections and/or by series terminals. It is e.g. possible that one series terminal provides one of the exposed sections 19 of the return line 8a and one of the exposed sections of the feeding line 8b. The exposed sections 19 of the return line 8a are not necessarily required for a residual current to flow.

[0100] As in the embodiment shown in FIG. 1, these exposed sections 19, in particular of the feeding line 8b, are arranged in a bottom area or bottom volume of the housing 2, in particular below the inverter 4 and the auxiliary electronic components 5, 6, 7 with respect to the vertical direction z. In other words, the exposed sections 19 are arranged in between the inverter 4 and the bottom side of the housing 2 or the carrier element 17 in an installed state of the housing 2. It is, for instance, possible, that series terminals are mounted to a bottom plate of the housing 2, wherein the series terminals are also arranged in the inner volume 3 in which the inverter 4 and the auxiliary electronic components 5, 6, 7 are arranged.

[0101] If fluid collects in the inner volume 3 of the housing 2, this fluid will collect in the bottom area which provides a fluid collection volume of the housing 2. Before contacting or enclosing parts of the inverter 4, this fluid will contact the exposed sections 19 and thus generate a residual current between at least one exposed section 19 of the feeding line 8b and the housing 2 which can be detected by the RCD 12.

[0102] FIG. 3 shows a schematic block diagram of an inductive power transfer unit 1 according to another embodiment of the invention. In contrast to the embodiment shown in FIG. 2, the RCD 12 has no trip signal interface 13. The unit 1 comprises an evaluation unit 20, where power is supplied to the evaluation unit 20 independently of the power supply to the auxiliary electronic components 5, 6, 7. The evaluation unit 20 can monitor a power supply state of the auxiliary electronic components, e. g. of the control unit 5. This can e. g. performed by a signal connection between the evaluation unit 20 and the control unit 5. If the evaluation unit 20 detects that no power supply is provided to the auxiliary electronic components, a trip signal for the circuit breaker 14 of the main power supply line 10 can be generated.

[0103] FIG. 4 shows a schematic block diagram of an inductive power transfer unit 1 according to another embodiment of the invention. In contrast to the embodiment shown in FIG. 2, the feeding line 8b of the auxiliary power supply line 8 is fitted with one exposed section 19. The housing 2 can be made of an insulating, i.e. non-conductive, material but can provide at least one electrically conductive portion 21. The electrically conductive portion 21 can e.g. be electrically connected to a ground potential, e.g. via the carrier element 19. A residual current can flow between the exposed section 19 and the conductive portion 21 of the housing 2 if fluid collects in the inner volume 3 of the housing 2 and contacts at least one of the exposed sections 19 and the conductive portion 21. It is shown that the exposed section 21 is also arranged in a bottom area or bottom volume of the housing 2, in particular on a bottom plate of the housing 2.

[0104] FIG. 5 shows a schematic block diagram of an inductive power transfer unit 1 according to another embodiment of the invention. In contrast to the embodiment shown in FIG. 4, the housing 2 does not comprise or provide an electrically conductive portion 21 but is made of an insulating material. In addition to the neutral line 8a and the feeding line 8b, the unit 1, in particular the auxiliary power supply line, can comprise an additional protective line 8c (PE line) which is connected to corresponding terminals of the auxiliary electronic components 5, 6, 7 and the auxiliary power supply unit 9. The protective line 8c is connected to a ground potential.

[0105] Similar to the feeding and the neutral line 8a, 8b, the protective line 8c comprises an internal section which is arranged within the inner volume 3 of the housing 2 and an external section, which is arranged outside the housing 2. The housing 2 can comprise an inlet for the protective line 8c. Further, only the neutral line 8a and the feeding line 8b of the auxiliary power supply line 8 are fitted with the RCD 12. In other words, the protective line 8c is not wired through the RCD 12.

[0106] Schematically indicated is one exposed section 19 of the feeding line 8b and one exposed section of the protective line 8c. The exposed sections 19 can e.g. be provided by uninsulated sections and/or by a series terminal.

[0107] Further shown is that the exposed sections 19 are arranged in a bottom area or bottom volume of the housing 2, in particular below the inverter 4 and the auxiliary electronic components 5, 6, 7 with respect to the vertical direction z. The bottom area or bottom volume provides a fluid collection volume of the housing 2.

[0108] In the embodiment shown in FIG. 5, a residual current can flow between the exposed sections 19 of the feeding line 8b and the protective line 8c. Such a residual current will cause a change of the RCD 12 from a closed state to an open state.