Pole-niche-integrated starting-current limiter

Abstract

Starting current limitation system 20 having at least a first electrical connection component 30 which can be connected to a battery pole 12, a second electrical connection component 34 which can be connected to a starter 18, and a parallel circuit which is connected between the first connection component 30 and the second connection component 34 and which comprises a branch 24a having a amperage control device 24 and a branch 22a having an electrical resistor 22. An optimization of structural space is achieved when the branch 22a having the electrical resistor 22, the branch 24a having the amperage control device 24 and the first connection component 30 are arranged inside a pole niche 26a of the battery pole 12.

Claims

1. Starting current limitation system, in particular for motor vehicles having an internal combustion engine, comprising: at least a first electrical connection component which can be connected to a battery pole; a second electrical connection component which can be connected to a starter, and a parallel circuit which is connected between the first electrical connection component and the second electrical connection component and which includes a branch having an amperage control device and a branch having an electrical resistor, wherein the amperage control device includes a first switch network having semiconductors wherein the electrical resistor is connected to the first electrical connection component by means of a second switch network, such that the first and the second switch network isolate a connection line between the starter and the starting current limitation system from electric potential at finalization of a starting operation of the starter.

2. Starting current limitation system according to claim 1, wherein the resistor is formed as a flat component.

3. Starting current limitation system according to claim 1, wherein the resistor extends at least partially parallel with a boundary wall and/or an outer edge of the pole niche.

4. Starting current limitation system according to claim 1, wherein the resistor is formed as a dimensionally stable angled member.

5. Starting current limitation system according to claim 1, wherein the resistor is a flat component and the width extent direction thereof extends in portions substantially parallel with a longitudinal axis of the battery pole.

6. Starting current limitation system according to claim 1, wherein the first electrical connection component is a battery pole terminal.

7. Starting current limitation system according to claim 1, wherein the first connection component has at least a first electrical tap which is connected to the battery pole terminal and a second electrical tap which is connected to the battery pole terminal and in that the first tap is connected to the branch having the amperage control device and the second tap is connected to the branch having the electrical resistor.

8. Starting current limitation system according to claim 1, wherein the first electrical connection component has a current distribution rail.

9. Starting current limitation system according to claim 8, wherein the current distribution rail has a first connection region in order to be connected to the battery pole terminal and in that the current distribution rail has a second connection region which extends at angles with respect to the first connection region.

10. Starting current limitation system according to claim 9, wherein the second connection region is formed as a flat component.

11. Starting current limitation system according to claim 9, wherein the second connection region extends at least partially parallel with a boundary wall or an outer edge of the pole niche.

12. Starting current limitation system according to claim 9, wherein the second connection region is formed as a dimensionally stable angled member.

13. Starting current limitation system according to claim 9, wherein the second connection region is a flat component and in the width extent direction thereof extends in portions substantially parallel with a longitudinal axis of the battery pole.

14. Starting current limitation system according to claim 1, wherein the first electrical connection component has an electrical connection for a generator and/or a consumer network of the motor vehicle.

15. Starting current limitation system according to claim 1, wherein the first and/or the second switch network has at least two switches which are electrically connected in parallel.

16. Starting current limitation system according to claim 1, wherein the branch having the amperage control device is arranged primarily inside a first circle segment around the battery pole and in that the branch having the electrical resistor is arranged primarily within a second circle segment which is different from the first circle segment around the battery pole.

17. Starting current limitation system according to claim 1, wherein the resistor is guided in portions along the boundary wall of the pole niche or the outer edge of the pole niche.

18. Starting current limitation system according to claim 9, wherein the second connection region is guided in portions along the boundary wall of the pole niche or the outer edge of the pole niche.

Description

(1) The subject-matter is explained in greater detail below with reference to drawings which show embodiments. In the drawings:

(2) FIG. 1 shows a voltage path on a conventional battery during a start-up operation without starting voltage drop limitation;

(3) FIG. 2 shows a schematic network topology between battery, starter, generator and consumer with a starting voltage drop limitation;

(4) FIG. 3 shows a schematic topology of a starting current limitation system with reversible switching off;

(5) FIG. 4a is a view of a battery pole;

(6) FIG. 4b is a plan view of a battery with battery poles;

(7) FIG. 5 is a schematic plan view of a spatial arrangement of a starting current limitation system;

(8) FIG. 6 is a plan view of another spatial arrangement of a starting current limitation system;

(9) FIG. 7 is a view of a possible arrangement of a starting current limitation system.

(10) FIG. 1 shows the curve of the voltage 2 over a time 4 of approximately 1 second during a start-up operation. Two voltage curves 6a and 6b are shown and are typical of a start-up operation. The voltage curves are preferably tapped between the battery positive pole and the battery negative pole. It can be seen that the voltage curves 6a, 6b are similar to each other. The voltage curves 6a, 6b show the conventional, non-regulated behaviour of a voltage at battery poles in the start-up operation.

(11) It can be seen that, at the time of starting-up at time Te, the voltages drop and the voltage drops below a voltage value of 8 volt. Subsequently, the voltage recovers to then fall below a voltage value of 9 Volt at a time T1 again. Subsequently, the voltage further recovers and reaches the initial value of approximately 12 Volt after approximately 1 second.

(12) The first voltage drop at the time Te can be compensated by means of buffer capacitors in the control devices so that it is not below 9 Volt. Afterwards, however, the buffer capacitors are discharged and, at the latest at the time T1 in the case of the new voltage drop below 9 Volt, consumers in the consumer network of the vehicle would be affected. Malfunctions and failures of consumers may occur. In addition to dropouts of navigation systems and entertainment systems within the vehicle, which are less safety-critical, failures of safety-relevant components may also occur, which it is imperative to avoid. That is to say, in addition to a gain in terms of comfort, safety aspects are also relevant to the starting current limitation.

(13) The electrical topology of a starting current limitation system is illustrated by way of example in FIGS. 2 and 3.

(14) FIG. 2 shows a battery 8 with a first battery pole 10 and a second battery pole 12, wherein the pole 12 is preferably the positive pole. From the battery pole 12, a first line 14a branches to a consumer network 14. The consumer network 14 may be formed by comfort functions, such as, for example, air-conditioning system, navigation system, entertainment system and the like, and safety-relevant systems such as, for example, airbag control devices, driver assistance systems, power steering and the like. The consumer network 14 requires from the battery 8 a constant voltage which is regularly above 9 Volt. If the battery voltage drops below such a limit, malfunctions may occur within the consumer network 14. An additional line 16a branches off to a generator 16. The generator 16, also known as a dynamo, constitutes during operation an electrical energy source in order to charge the battery 8.

(15) There is further connected to the pole 12 a line 18a which may also be constructed as a pole terminal and which leads to a starter 18. The starter 18 is an electrical machine which is used to start the internal combustion engine. At the time of starting up, the internal combustion engine has no torque and can be started up only by an external torque which is provided by the starter 18.

(16) The starter 18 is an electrical machine which has a high torque which in the stopped state as an inductive load has only a very low resistance. This means that, via the starter 18, at the time of starting up, a considerable current flows from the battery 8, which can lead to the voltage drops shown in FIG. 1. In order to prevent such voltage drops, there is provided a starting current limitation system 20 which is formed by a branch 22a having a resistor 22 and a branch 24a having a amperage control device 24.

(17) The operation of such a starting current limitation system 20 is known adequately. At the time of starting up, current flows exclusively via the branch 22a. After a short time, for example, 100 ms, the branch 24a is added and a parallel circuit which comprises the resistor 22 and the amperage control device 24 and via which the current flows is formed. The amperage control device 24 may be operated in a pulsed manner so that an averaged resistance is adjusted via the branch 24a. The amperage can thereby be adjusted via the starting current limitation system 20 in such a manner that the voltage at the battery 8 across the poles 10 and 12 does not fall below 9 Volt. A corresponding electronic control system is provided.

(18) FIG. 3 shows a similar topology to that set out in FIG. 2. In addition to the subassemblies used in FIG. 2, an additional switch network 22b is provided in the branch 22a having the resistor 22. The amperage control device 24 and the switch network 22b may be formed by means of semi-conductor switches, in particular semi-conductor switches which are connected in parallel. The switches which are provided in the switch network 22b are closed during the start-up operation. After the start-up operation has ended, the switches of the switch network 22b and the switches of the amperage control device 24 can be completely opened so that the line 18a between the starting current limitation system 20 and starter 18 is potential-free. This prevents corrosion on the line 18a and increases the safety in the event of a crash.

(19) The starting current limitation systems 20 which have been set out have to be installed in the available structural space. According to the invention, it has been recognised that this is possible in the pole niche, preferably the battery positive pole 12. FIG. 4a shows a battery 8 having a pole 12 and a pole 10. The two poles 10, 12 are each surrounded by a pole niche 26a, 26b. The pole niche 26a is delimited by the two boundary walls 8a and 8b of the battery 8 and the outer edges 8c, 8d of the battery 8.

(20) The spatial orientation of the boundary walls 8a, 8b and the outer edges 8c, 8d is illustrated below in the x, y, z coordinate system shown in FIG. 4a. The boundary wall 8a preferably extends parallel with the x-z plane. The boundary wall 8b preferably extends parallel with the y-z plane. The outer edge 8c extends parallel with the x axis and the outer wall 8d extends parallel with the y axis. The longitudinal extent direction 12a of the battery pole 12 or the battery pole terminal extends parallel with the z axis.

(21) Between the pole niche 26a and the pole niche 26b there extends an offset 26c whose volume can also be used in the construction of the starting current limitation system 20.

(22) The structure of the battery 4a substantially corresponds to DIN EN 50342-2.

(23) The battery according to FIG. 4a is illustrated in FIG. 4b in a plan view. It is possible to see the faces of the pole niches 26a, 26b. The objective starting current limitation system 20 is preferably arranged inside the face of the pole niche 26a and may extend in the face of the offset 26c.

(24) FIG. 5 shows the arrangement of a starting current limitation system 20 in the pole niche 26a. It is possible to see that a battery pole terminal 28 is connected to the battery pole 12. A connection component which is constructed as a current distribution rail 30 is connected to the battery pole terminal 28 in a material bond. In the region of the connection between the battery pole terminal 28 and the current distribution rail 30, the current distribution rail 30 may be constructed as a flat member and, for example, extend parallel with the x-y plane. This would be a first electrical tap of the first connection member. The first connection member may extend from this first electrical tap into a second electrical tap, wherein the second electrical tap is arranged in an angled manner with respect to the first electrical tap.

(25) Preferably, the current distribution rail 30 may be constructed as a bent flat member, wherein the second electrical tap which is formed for connection to respective switches 32a, 32b may extend perpendicularly to the x-y plane. Preferably, the second electrical tap extends partially parallel with the x-z plane and partially parallel with the y-z plane. In particular, the region of the second electrical tap which is orientated in the direction of the switch 32a extends parallel with the y-z plane. The region which extends in the direction of the switch 32b is preferably arranged parallel with the x-z plane. The width extent direction of the current distribution rail in the region of the second tap preferably extends parallel with the z direction. An arrangement in a respective plane preferably means that the width extent direction of the respective flat member extends parallel with such a plane.

(26) The switches 32a are semi-conductor switches and correspond to the switches of the switch network 22b. The switches 32a connect the current distribution rail 30 to the resistor 22. The resistor is preferably formed as a dimensionally stable bent angled member. In particular, the resistor 22 is formed as a flat component, wherein the width extent direction thereof extends in the direction of the z axis. A first member of the resistor 22 may extend parallel with the x-z plane. A second member which is angled relative thereto may preferably extend parallel with the y-z plane. Starting from the first member, the resistor 22 extends from the switches 32a to the second connection component 34.

(27) The current distribution rail 30 is connected with the first tap thereof to the switches 32b which are formed for amperage control as required and are controlled accordingly. Via these switches 32b, the current distribution rail 30 is connected to the second connection component 34. Starting from the second connection component 34, the line 18a extends to the starter 18. The electrical connection between the line 18a and the second connection component 34 may extend into the offset 26c.

(28) FIG. 6 shows another embodiment of an arrangement of a starting current limitation system in a pole niche 26a. It can be seen that, starting from the battery pole terminal 28, the current distribution rail 30 has a first electrical tap 30a which is connected to the battery pole terminal and a second electrical tap 30b which is connected to the battery pole terminal 28. The electrical taps 30a, 30b are both electrically connected to the battery pole terminal 28 but are spatially separated from each other. In contrast, the current distribution rail 30 according to FIG. 5 is integral and connected in each case to a switch network 32a, 32b at the distal ends thereof.

(29) Starting from the first tap 30a which may be constructed as a flat component and which may, for example, be U-shaped, a plurality of switches of the switch network 32b may extend. These switches of the switch network 32b may be connected to an end of a second connection component 34 which engages in the U of the first tap 30a. The first tap 30a, the second tap 30b and/or the battery pole terminal 28 may have connections for the generator line 16a and the line 14a to the consumer network 14.

(30) The second electrical tap 30b may be connected to the resistor 22 by means of a switch network 32a. In this instance, the resistor extends as a flat component parallel with the y-z plane.

(31) As can be seen in FIGS. 5 and 6, the connection between the respective switch network 32a, 32b and the resistor 22 can be constructed in two parts. In particular, the resistor may be formed from a different alloy from the flat components of the switch networks 32a, 32b. The flat components which connect the switch networks 32a, 32b to the resistor are preferably of copper or alloys thereof. The resistor 22 is preferably of a resistance alloy, such as, for example, a copper/manganese alloy with other components comprising nickel, aluminium, tin and/or iron.

(32) FIG. 7 shows another schematic view of a structure of a starting current limitation system 20. It can be seen that, starting from the battery pole terminal 28, there extends an electrical tap 29 which extends parallel with the x-y plane and which is connected to the current distribution rail 30. Starting from this electrical tap 29, the current distribution rail 30 is bent in such a manner that a first end 30 in the assembled state extends parallel with the boundary wall 8b and along the boundary wall 8b. A second end 30 extends parallel with the boundary wall 8a and along it.

(33) The first end 30 opens in a housing 36b in which the switch network 32b is accommodated. Starting from this switch network 32b there extends from the housing 36b an electrical tap 33 which is formed as a flat component and which is connected to the resistor 22 outside the housing 36b. The tap 33 is connected to the connection component 34.

(34) The second end 30 of the current distribution rail 30 extends in a housing 36a in which the switch network 32a is arranged.

(35) The width extent direction of the resistor is parallel with the z axis. A first member 22 of the resistor 22 extends parallel with the x axis in the assembled state. A second member 22 of the resistor extends parallel with the y axis in the assembled state.

(36) The member 22 is connected to an output of the switch network 32a. The member 22 is connected to an output of the switch network 32b.

(37) The resistor 22 is a bent angled member which starting from the member 22 extends into the member 22 which extends at right angles thereto. The member 22 extends parallel with and along the outer edge 8c. The member 22 extends parallel with and along the outer edge 8d. The resistor 22 opens in the second connection component 34.

(38) In the space defined between the members 22 and 22, an electrical tap 38 of the battery pole terminal 28 is provided. Via this electrical tap 38, which is preferably spatially arranged between the battery pole terminal 28 and the resistor 22, a consumer network and/or a generator can be electrically connected to the battery pole 12.

(39) The branch having the resistor 22 extends in the region of the outer edges 8c and 8d, whereas the current distribution rail 30 and the branch having the amperage control device formed by the switch network 32b is arranged in the region of the boundary wall 8b and the outer edge 8c. Consequently, the faces used by the respective branches intersect only partially and the respective branches are mainly arranged in mutually different circle segments around the battery pole 12.

(40) Preferably, the current distribution rail 30 engages around the battery pole 12 in a first circle segment and the resistor 22 engages around the battery pole 12 in a second circle segment.

(41) As a result of the arrangement of the starting current limitation system 20 in the pole niche 26a, a structural space optimisation is achieved with electrical safety being ensured.