Sensor, Circuit Breaker, Charging Cable and Charging Station

Abstract

A sensor includes a passage in a shield with a clear width of 25.2 to 32 mm, which provides a higher sensitivity to electrical differential current, and more particularly for determining the universal-current sensitive determination of an electric differential current. The sensor can be a part of a circuit breaker, a charging cable and a charging station.

Claims

1. Sensor for the universal-current sensitive determination of an electric differential current, the sensor comprising a magnetic field-sensitive component, a first main winding, a test winding, and a shield, the magnetic field-sensitive component comprising a through-opening, the through-opening of the magnetic field-sensitive component being formed, in cross section, as an oval having two axes of symmetry, the first main winding and the test winding surrounding the magnetic field-sensitive component by means of a plurality of windings in each case, the shield comprising a receiving space which is designed for receiving the magnetic field-sensitive component, the first main winding, and the test winding, the receiving space of the shield being delimited, in the radial direction, by a shield outside wall and a shield inside wall, the shield inside wall defining a through-opening of the shield, the through-opening of the shield being formed as an oval having two axes of symmetry, the shield comprising a peripheral gap in the region of the shield inside wall, the sensor being designed for being arranged around at least two electrical conductors, the through-opening of the magnetic field-sensitive component haying at least one clear width along an axis of symmetry, wherein the at least one clear width is in a range between 25.2 and 32 mm, preferably a range between 25.5 and 29 mm, and particularly preferably between 25.8 and 27 mm.

2. Sensor according to claim 1, characterized in that the magnetic field-sensitive component is encased by an insulator, the insulator being arranged between the magnetic field-sensitive component and the first main winding, and between the magnetic field-sensitive component and the test winding.

3. Sensor according to claim 1, wherein the sensor comprises a second main winding, the second main winding surrounding the magnetic field-sensitive component and/or the insulator by means of a plurality of windings.

4. System according to claim 1, wherein the sensor comprises a spacer ring, the spacer ring being arranged between the shield inside wall and the first main winding.

5. Sensor according to claim 1, wherein the shield comprises a coating, in particular an electrically insulating coating.

6. Sensor according to claim 1, wherein the shield has a material thickness in a range between 0.25 mm and 0.45 mm, preferably in a range between 0.3 mm and 0.4 mm, and particularly preferably in a range between 0.32 mm and 0.38 mm.

7. Sensor according to claim 1, wherein the peripheral gap has a gap width in a range between 0.1 mm and 2.0 mm, preferably in a range between 0.3 mm and 1.7 mm, and particularly preferably in a range between 0.6 mm and 1.3 mm.

8. System according to claim 1, wherein the sensor comprises an electrical connector, electrical connector comprising a support plate a connector neck, and a plurality of electrical contacts, the electrical connector comprising two electrical contacts, at least for each winding, the electrical contacts being arranged outside the shield outside wall, in the radial direction, the support plate being arranged between the shield outside wall and the first main winding, the connector neck extending through an opening in the shield outside d call and interconnecting the support plate and the electrical contacts, the support plate and the connector neck each comprising a corresponding recess (92), the recess (92) being designed for receiving the two electrical wires, which are operatively connected to each winding, from the receiving space, and guiding these to the electrical contacts, from the receiving space and through the opening in the shield outside wall, the recess comprising a notch, in a direction in parallel with the shield outside wall, through which notch the electrical wires can be inserted into a central region of the recess.

9. Circuit breaker for interrupting an electrical circuit in the case of differential currents in the electrical circuit exceeding a threshold value, comprising a sensor according to claim 1, an operating circuit, an electronic data processing and analysis unit, and a switching apparatus, wherein the sensor is arranged around at least two electrical conductors which form the electrical circuit, the switching apparatus being designed for interrupting the electrical circuit, wherein the operating circuit is designed for operating the sensor, wherein the electronic data processing and analysis unit is designed for analyzing sensor signals of the sensor, wherein the electronic data processing and analysis unit is designed, upon identification of an electrical differential current, in particular in the case of universal-current sensitive identification of a differential current, having a current strength greater than the threshold value, in particular an adjustable threshold value, to actuate the switching apparatus such that the switching apparatus interrupts the electrical circuit.

10. An apparatus comprising a charging cable for charging an electric vehicle and a sensor according to claim 1.

11. An apparatus comprising a charging station for charging an electric vehicle and a sensor according to claim 1.

12. An apparatus comprising a charging cable for charging an electric vehicle, and a circuit breaker according to claim 9.

13. An apparatus comprising a charging station for charging an electric vehicle, and a circuit breaker according to claim 9.

Description

[0299] Further advantages, details and features of the invention can be found in the following, from the explained embodiments. In the figures, in detail:

[0300] FIG. 1 is a schematic view of an arrangement of the sensor according to the invention in an electrical circuit;

[0301] FIG. 2 is a schematic view of a physical operative connection upon closing the electrical circuit;

[0302] FIG. 3 schematically shows a dynamic development of the magnetic flux density over time, upon closing the electrical circuit, at a point, by way of example, in the magnetic field-sensitive component;

[0303] FIG. 4 schematically shows the physical correlation between the clear width of the magnetic field-sensitive component, the curve of the tendency of the sensor to incorrect activation depending on the clear width, and the curve of the smallest measurable differential current of a sensor depending on the clear width;

[0304] FIG. 5 is a schematic cross section of a sensor according to the invention;

[0305] FIG. 6 shows various schematic views of an electrical connector.

[0306] In the following description, the same reference signs refer to identical components or features, and therefore a description given with reference to one figure, with respect to a component, also applies for the other figures, and therefore a repeated description is omitted. Furthermore, the individual features which have been described in connection with one embodiment can also be used separately in other embodiments.

[0307] The sensor 100, shown schematically in FIG. 1, is arranged around the electrical conductors 110, 120, through which a designated electrical current 112, 114 flows into and back out of the electrical circuit (not shown) monitored by the sensor 100.

[0308] In this case, the electrical current 112 flows into the electrical circuit (not shown), monitored by the sensor 100, via the phase conductor 110, and back out via the neutral conductor 120.

[0309] Upon activation of the voltage supply (not shown) in an electrical circuit (not shown), a dynamic physical operative connection results, in FIG. 2, between the magnetic fields 114, 124 arising around the electrical conductors 110, 120, and the regional magnetic flux density 116, 118 in the magnetic field-sensitive component 10.

[0310] The magnetic fields 114, 124 emanating from the electrical conductors 110, 120 influence the magnetic field-sensitive component 10, upon activation of the voltage supply (not shown), regionally and in a time-limited manner, in different ways, such that briefly regionally opposing magnetic flux densities 116, 126 are established in the magnetic field-sensitive component 10.

[0311] During the compensation process thereof, in FIG. 3, over time 130, considered at a point by way of example (not shown) in the magnetic field-sensitive component 10, the brief regionally opposing magnetic flux densities 116, 126 in the magnetic field-sensitive component 10 lead to dynamic behavior of the magnetic flux density in the form of an oscillation of the magnetic flux density 132.

[0312] This oscillation of the magnetic flux density 132, as a result of the activation of the current supply (not shown) for the electrical circuit considered (not shown), proceeds in a damped manner, and approaches the temporal threshold value thereof along the asymptotes 132, 134.

[0313] In this case, the brief oscillation of the magnetic flux density 132 also leads to a physical interaction (not shown) with the test winding (not shown) and/or the first main winding and/or a second main winding, resulting in a sensor signal (not shown), which can be interpreted as a differential current (not shown) that exceeds a defined threshold value (not shown). This can also be described as an activation fault.

[0314] The correlation, shown in FIG. 4, between the clear width 12 of the through-opening (not shown) of the magnetic field-sensitive component 10, the tendency to incorrect activation 140 of a circuit breaker (not shown) designated to use the sensor 100, and the smallest differential current 150 that can be measured by the sensor 100, shows that there is an optimal value 160 for the clear width 12 of the through-opening (not shown) of the magnetic field-sensitive component 10, at which a good compromise is found between the smallest measurable differential current 150 and the tendency to incorrect activation 140.

[0315] In the view shown schematically here, said optimal value 160 is located at the intersection of the curves 142, 152.

[0316] Furthermore, an optimal range 165 for the clear width 12 of the through-opening (not shown) of the magnetic field-sensitive component 10 results, which is arranged around the optimal value 160.

[0317] The sensor 100 in FIG. 5 essentially consists of a magnetic field-sensitive component 10, an insulator 20 that surrounds the magnetic field-sensitive component 10, a main winding 30, a test winding (not shown), a spacer ring 40, a shield 50, an electrical connector 60, and a plurality of electrical contacts 70.

[0318] The insulator 20 is formed in two parts, the individual parts (not shown) of the insulator 20 being interconnected in a form-fitting manner.

[0319] The main winding 30 is connected by means of an electrical wire 75 to the electrical contact 70 which is borne by the electrical connector 60.

[0320] The shield 50 is formed in two parts and forms a peripheral gap 55 on the shield inside wall 58.

[0321] The electrical connector 60 in FIG. 6 essentially consists of a support plate 80, a connector neck 90, and a plurality of electrical contacts 70.

[0322] Letter b) in FIG. 6 is a three-dimensional view of the electrical connector 60.

[0323] Letter a) in FIG. 6 is a front view of the electrical connector 60, the front view being shown viewed from the outside, with respect to the designated sensor.

[0324] Letter c) in FIG. 6 is a plan view of the electrical connector 60. Furthermore, the cutting guides A-A and B-B are shown.

[0325] Letter d) shows the section A-A through the electrical connector 60.

[0326] Letter e) shows the section B-B through the electrical connector 60.

[0327] Letter f) in FIG. 6 is a front view of the electrical connector 60, the front view being shown viewed from the inside, with respect to the designated sensor.

[0328] Letter g) in FIG. 6 is a side view of the electrical connector 60.

[0329] The support plate 80 is designed to be received in the receiving space (not shown) of the shield (not shown).

[0330] The connector neck 90 connects the plurality of electrical contacts 70 to the support plate 80.

[0331] The connector neck 90 comprises a recess 92 which is designed for receiving the two electrical wires (not shown), which are operatively connected to each winding (not shown), from the receiving space (not shown), and guiding these to the electrical contacts (70), from the receiving space (not shown) and through the opening (not shown) in the shield outside wall (not shown).

[0332] The recess 92 further comprises a notch 94, in a direction in parallel with the shield outside wall (not shown), through which notch the electrical wires (not shown) can be inserted into a central region (not shown) of the recess 92.

[0333] The notch 94 makes it possible to insert electrical wires (not shown) transversely into the recess 92, individually or in bundles, in a simple manner, it being necessary, in the process, for each individual electrical wire (not shown) to pass the notch 94 at the constriction (not shown) thereof. In this case, the constriction (not shown) of the notch 94 is designed such that an electrical wire (not shown), once inserted into the recess 92, can leave the recess 92 again, transversely to the longitudinal direction (not shown) of the recess 92, only with significant effort, and thus remains in the protective region (not shown) of the recess 92, in a designated manner.

LIST OF REFERENCE SIGNS

[0334] 10 magnetic field-sensitive component [0335] 12 clear width [0336] 20 insulator [0337] 30 main winding [0338] 40 spacer ring [0339] 50 shield [0340] 55 peripheral gap [0341] 58 shield inside wall [0342] 60 electrical connector [0343] 70 electrical contact [0344] 75 electrical wire [0345] 80 support plate [0346] 90 connector neck [0347] 92 recess [0348] 94 notch [0349] 100 sensor [0350] 110 electrical conductor/phase conductor [0351] 112 direction of the electrical current [0352] 114 magnetic field [0353] 116 magnetic flux density [0354] 120 electrical conductor/neutral conductor [0355] 122 direction of the electrical current [0356] 124 magnetic field [0357] 126 magnetic flux density [0358] 130 time axis [0359] 132 oscillation of the magnetic flux density [0360] 134 asymptote [0361] 136 asymptote [0362] 140 tendency to incorrect activation [0363] 142 curve of the tendency to incorrect activation [0364] 150 smallest measurable differential current [0365] 152 curve of the smallest measurable differential current [0366] 160 optimal value [0367] 165 optimal range