DE102024107819A1 - Coupling device, charging plug system, charging device, modular system for the production of different charging plug systems, charging station and process - Google Patents

Abstract

The invention is based on a coupling device (102), in particular a quick-coupling device, at least for connecting a preferably fluid-cooled, high-performance charging cable (10), for example of an electric vehicle charging station (12), to a charging plug (14), which is provided for establishing an energy-transmitting connection of the high-performance charging cable (10) to a charging socket (16) of an external system (18), for example a charging socket (16) of an electric vehicle, comprising a coupling housing (20), which is provided for receiving, preferably in a fluid-tight manner, a cable end (26) of the high-performance charging cable (10).
It is proposed that the coupling device (102) has a plug-in connector unit (40) which continues at least one cooling fluid line (22, 28, 30, 32, 34, 36) and/or at least one power line (24, 38) of the cable end (26) of the high-performance charging cable (10), which is provided for a positive and/or non-positive insertion into a charging cable connection unit (42) of the charging plug (14).

Description

State of the art

The invention relates to a coupling device according to the preamble of claim 1, a charging plug system according to claim 22, a charging device according to claim 23, a modular system according to claim 24, a charging station according to claim 25 and a method according to the preamble of claim 26.

Coupling devices for connecting high-performance charging cables from electric vehicle charging stations to charging plugs have already been proposed. However, these coupling systems are extremely complex to assemble and disassemble. In many cases, the high-performance charging cable must be cut, thus partially destroying, each time the charging plug is removed.

The object of the invention is, in particular, to provide a generic device with advantageous properties with regard to assembly and/or disassembly. This object is achieved according to the invention by the features of the independent and subordinate patent claims, while advantageous embodiments and further developments of the invention can be found in the subclaims.

Advantages of the invention

The invention is based on a coupling device, in particular a quick-coupling device, at least for connecting a, preferably fluid-cooled, high-performance charging cable, for example of an electric vehicle charging station, to a charging plug, which is provided for establishing an energy-transmitting connection, in particular a charging energy-transmitting connection, of the high-performance charging cable to a charging socket of an external system, for example a charging socket of an electric vehicle, comprising a coupling housing, which is provided for receiving, preferably in a fluid-tight manner, a cable end of the high-performance charging cable.

It is proposed that the coupling device comprise a plug-in connector unit that extends at least one cooling fluid line and/or at least one power line from the cable end of the high-performance charging cable, which connector unit is provided for positive and/or force-fitting insertion into a charging cable connection unit of the charging plug. This advantageously simplifies the assembly and/or disassembly of charging plugs on high-performance charging cables, in particular fluid-cooled high-performance charging cables. Service work, such as replacing, repairing, and/or maintaining a charging plug and/or a high-performance charging cable, can advantageously be significantly accelerated. This also allows for economic advantages. In particular, the proposed coupling device can reduce downtime at a charging station/charging column for replacing a charging plug or the like to a few minutes. Furthermore, flexibility can advantageously be increased. If, for example, a change in the charging plug design or in the charging plug layout or configuration is required or desired, this can be done without significant labor and expense. In addition, the described invention can advantageously enable a substantially independent assembly of high-performance charging cables and charging plugs, e.g. during their (further) development, which can advantageously shorten delivery times and/or technical development cycles and increase availability.

The coupling device is designed in particular as a quick-coupling device, which can preferably be assembled and/or disassembled in a few minutes, e.g., in less than 10 minutes, preferably in less than 5 minutes. In particular, the coupling device can be mounted at least on the charging plug without crimping, welding, and/or gluing. In particular, the coupling device can be disassembled at least from the charging plug without cutting, cutting off, and/or breaking or bending components of the charging plug or the high-performance charging cable. In particular, the coupling device allows the charging plug to be separated from the high-performance charging cable and vice versa without causing any damage.

In particular, the coupling device is a direct current coupling device which is provided for coupling a direct current-carrying high-performance charging cable to a direct current charging plug. The high-performance charging cable is in particular a high-performance direct current charging cable. The high-performance charging cable is in particular provided for transmitting peak charging powers above 100 kW, advantageously above 300 kW, preferably above 500 kW and particularly preferably above 1 MW. In particular, the high-performance charging cable is designed as a megawatt charging cable. The coupling device can be provided for connecting various high-performance charging cables with different peak charging powers, in particular different diameters. However, It is also conceivable that different coupling devices with different dimensions but otherwise identical construction are provided for different high-performance charging cables. The high-performance charging cable is preferably fluid-cooled. For this purpose, the high-performance charging cable can have one or more cooling fluid lines. The cooling fluid lines of the high-performance charging cable can run at least partially outside and/or at least partially inside current-carrying lines of the high-performance charging cable/outside power lines of the high-performance charging cable. For example, it is conceivable that some of the cooling fluid lines run separately from power lines and that another part of the cooling fluid lines runs in a center of power lines. A cooling fluid moved in the cooling fluid lines is preferably (distilled) water. However, other common coolants, in particular those that have already proven themselves in charging cables, are also conceivable. The cooling fluid lines connect an active or passive cooling device, which can be integrated, for example, into an electric vehicle charging station, at least to the charging plug. The cooling fluid can be provided, among other things, for cooling a plug connection between the charging plug and the charging socket during a charging process. The high-performance charging cable preferably has a diameter of more than 2 cm, more preferably more than 3 cm. The high-performance charging cable preferably has a diameter of less than 15 cm, more preferably less than 10 cm. The high-performance charging cable can be a cable of type 2x70 mm ² , type 5x50 mm ² , type 2x35 mm ² or another type. The high-performance charging cable can be provided with a coupling device on one side, in particular on the charging plug side. The high-performance charging cable can be provided with a coupling device on both sides, in particular on the charging plug side and the charging station side. “Provided” should be understood in particular to mean specially programmed, designed and/or equipped. The fact that an object is intended for a specific function should be understood in particular to mean that the object fulfills and/or executes this specific function in at least one application and/or operating state.

The charging plug is designed, in particular, as a direct current charging plug. The charging plug preferably has a standardized and/or known charging plug geometry that can be connected to commercially available charging sockets (such as MCS, CCS, NACS, etc.). The charging plug geometry for connecting the charging plug to the charging socket is separate and different from the plug connector unit of the coupling device. In addition to the charging plug geometry, the charging plug has the charging cable connection unit. The charging cable connection unit is separate and different from the charging plug geometry that can be connected to the charging socket. The charging cable connection unit can be designed as a plug (male) or a socket (female). The plug or socket geometry of the charging cable connection unit is different from commercially available geometries such as those mentioned above by way of example. The plug or socket geometry of the charging cable connection unit is preferably different from an MCS geometry, a CCS geometry, and a NACS geometry. The charging plug preferably has a handle and is manually operable, in particular plugged and unplugged. The external system can, in particular, be any type of electric vehicle, electric aircraft, electric ship, or other device to be supplied with electrical energy.

The coupling housing preferably encloses the cable end of the high-performance charging cable. The coupling housing preferably provides a fluid-tight seal between the cable end of the high-performance charging cable and the connector unit. The connector unit forms, in particular, a power interface, in particular a direct current interface, at least for transferring power to power lines of the charging plug. In addition to the power interface, the connector unit preferably forms a cooling fluid interface, at least for transferring cooling fluid to cooling fluid lines of the charging plug. The term "continuing" a line should be understood, in particular, to mean that the connector unit forms a connection option/connection point at which a conducted medium (cooling fluid line) and/or conducted electrical energy (power line) can be transferred, preferably at least substantially losslessly, from the high-performance charging cable, preferably to the charging plug. In particular, the connector unit forms at least one electrical contact for continuing the power line, which is in line contact with one of the power lines of the cable end accommodated in the coupling housing. In particular, the plug-in connector unit forms at least one hose or pipe connection for the continuation of the cooling fluid line, which is fluid-tightly connected to one of the cooling fluid lines of the cable end accommodated in the coupling housing. Preferably, the plug-in connector unit and the charging cable connection unit are designed to be complementary and compatible with each other. A connection by means of a "positive and/or non-positive insertion" is to be understood in particular as a detachable connection, wherein a holding force between two components is preferably transmitted by a geometric engagement of the components and/or a frictional force between the components. In particular, The connecting parts of the connector unit are aligned with the connecting parts of the charging cable connection unit by means of a positive fit, and are releasably secured to one another by friction and/or spring force. An additional locking and/or pull-out protection for the connection between the connector unit and the charging cable connection unit is optionally conceivable.

It is further proposed that the plug connector unit comprise at least one power connector element, which is provided for extending precisely one power line of the high-performance charging cable. This advantageously enables a simple, quick, and/or non-destructively detachable connection of the charging plug to power lines of the high-performance charging cable. Power connector elements are particularly intended to be electrically connected to the ends of the individual power lines of the high-performance charging cable, e.g., by crimping. For this purpose, the power connector elements preferably comprise a crimpable connection element, in particular a crimp sleeve, on a side facing into the interior of the coupling housing. The power lines and/or the cooling fluid lines are continued at least into the charging plug. The charging plug can then only extend the power lines to the outside, i.e., in particular, for transfer to charging sockets, and use the cooling fluid to cool the plug connection and/or the charging plug, or else discharge the cooling fluid externally. The extended power line is, in particular, one of at least two energy-transporting power lines of the high-performance charging cable. The power connector element, in particular, simultaneously forms one or two lines (for power and/or cooling fluid) and at least one form-locking element for creating the connection between the coupling device and the charging plug.

If the at least one energy connector element is also provided in addition to a continuation of exactly one cooling fluid line of the high-performance charging cable, a particularly high degree of compactness of the connector unit can advantageously be achieved and/or a particularly simple assembly and disassembly of the charging plug from the high-performance charging cable can be enabled. Thus, at least in this case, the energy connector element conducts both energy (current) and cooling fluid. Crimping on the connection element then simultaneously connects the cooling fluid line. The connector elements, in particular the energy connector elements of the connector unit, which continue one of the cooling fluid lines of the high-performance charging cable, each comprise one or more fluid seals. The fluid seals can be designed as quad rings, which are arranged on an outer circumference (in the case of a male connector element) or in an inner circumference (in the case of a female connector element) of at least these connector elements.

If, in addition, the connector unit additionally comprises at least one further power connector element, which is provided for a common continuation of exactly one further power line of the high-performance charging cable and exactly one further cooling fluid line of the high-performance charging cable, a particularly compact and/or easy-to-assemble and/or disassemble connector unit can advantageously be obtained. In particular, the further power connector element is formed separately from the power connector element. In particular, the two power connector elements are at least substantially identical in shape. In particular, the two power connector elements are aligned at least substantially parallel to one another.

Furthermore, it is proposed that the coupling device comprise a check valve, which is arranged at least in part in a fluid line channel of the connector unit formed by the power connector element and/or in a further fluid line channel of the connector unit formed by the further power connector element. This advantageously makes it possible to achieve a high level of operational reliability. Advantageously, the leakage of cooling fluid from the high-performance charging cable and/or from the coupling housing can be prevented. In particular, the check valve of the fluid line channels formed by the power connector element is provided to automatically close the associated fluid line channel in a fluid-tight manner when the connector unit is separated. In particular, the check valve closes the associated fluid line channel when a fluid pressure in the fluid line channel falls below a limit value. In particular, the check valve comprises a valve element which is deflected from the closed position to an open position by a cooling fluid pressure acting when the coupling device is connected. When the pressure drops, the valve element is automatically deflected back into a closed position, e.g., by a spring element. The check valve is preferably arranged at least partially in a part of the coupling device, e.g., in a male (power) connector element of the connector unit, which, during connection, is inserted into a receptacle, e.g., a plug-in receptacle of the charging cable connection unit of the charging plug. In particular, the check valve is located in the vicinity of a cooling fluid line opening of the respective (power) connector element. Another part of the check valve can be located in the charging connector. It is conceivable that the parts of the check valve are installed at the same time as the connector unit is connected to the charging cable connection unit.

It is also proposed that the power connector element(s) each have at least one electrical contact element for establishing intimate power line contact with corresponding connector elements, in particular plug receptacles, of the charging cable connection unit of the charging plug. This can advantageously ensure good and/or efficient power transmission. The electrical contact element can be designed, for example, as a contact spring or as another known electrical contacting element.

It is further proposed that at least the power connector element and/or at least the further power connector element comprise a support sleeve, which is intended to be inserted into an axial cavity of the power line when connected to the power line of the high-performance charging cable, in particular to the coupling device, and to counteract compression of this cavity when connecting the at least one power connector element and/or the further power connector element to the power line, in particular by crimping a crimpable connection element of the power connector element and/or the further power connector element onto the power line. This advantageously ensures high operational reliability of the coupling device. Advantageously, initial assembly of the coupling device to the high-performance charging cable can be simplified and/or made less prone to errors. Advantageously, optimal cooling performance can be guaranteed. The support sleeve is designed, in particular, as a cylindrical element. The support sleeve can be made of a metal, in particular steel, or of a plastic. The axial cavity of the power line of the high-performance charging cable is provided, in particular, for conducting the cooling fluid. The axial cavity of the power line of the high-performance charging cable forms, in particular, one of the cooling fluid lines of the high-performance charging cable, which preferably continues from the connector unit. The support sleeve assists in the sealing assembly of the coupling device to the high-performance charging cable. In particular, the support sleeve serves to keep the cooling fluid line of the power line of the high-performance charging cable open, even during and after assembly of the coupling device.

Furthermore, it is proposed that the plug connector unit additionally comprise at least one grounding connector element, which is provided at least for contacting a grounding conductor of the high-performance charging cable. This advantageously enables particularly simple and/or rapid assembly and/or disassembly of the high-performance charging cable with the charging plug, in particular by allowing several components of the high-performance charging cable to be connected to be connected and/or disassembled simultaneously/in a common assembly or disassembly step. The grounding connector element can comprise a crimpable connection element, in particular a crimp sleeve, on a side facing into the interior of the coupling housing. The crimpable connection element can be formed integrally or even monolithically with the grounding connector element. In particular, the two power connector elements in the plug connector unit are aligned at least substantially parallel to the grounding connector element. The grounding connector element is preferably designed purely for electrical contact. The grounding connector element is preferably uncooled.

It is additionally proposed that the plug-in connector unit additionally comprise at least one cooling connector element which is free of electrical contacts and which is provided for a continuation of at least one cooling fluid line of the high-performance charging cable. This advantageously enables a simple, quick, and/or non-destructively detachable connection of the fluid-cooled charging plug to the power lines of the high-performance charging cable. Cooling connector elements are particularly provided for being fluidly connected to the ends of the individual cooling fluid lines of the high-performance charging cable, e.g., by means of tube connectors. For this purpose, the cooling connector elements preferably comprise, on a side facing into the interior of the coupling housing, a plug-in tube, such as a plug-in cylinder, which is provided, in particular, for pulling on a hose, a plurality of hoses, or an adapter part, such as a Y-connector. The continued cooling fluid line is, in particular, one of at least two, in particular at least four, cooling fluid-transporting cooling fluid lines of the high-performance charging cable. The cooling connector element simultaneously forms a conduit for the cooling fluid. In particular, the cooling connector element has an at least substantially identical external shape to one or both power connector elements. In particular, the cooling connector element is aligned at least substantially parallel to one or both power connector elements.

If, in addition, the at least one cooling connector element is provided for a continuation of at least one further cooling fluid line of the high-performance charging cable, which is different from the cooling fluid line, this can advantageously achieve a high degree of compactness of the connector unit and/or enable particularly simple assembly and disassembly of the charging plug from the high-performance charging cable. Optionally, the coupling device can comprise at least one Y-connector, which is provided for merging the cooling fluid line and the further cooling fluid line and guiding them to the cooling connector element. Preferably, the merged outlet of the Y-connector is connected to the plug-in tube of the associated cooling connector element. Alternatively, the cooling fluid line and the further cooling fluid line can also be merged independently of a separate Y-connector, for example, by a rear side of cooling connector elements already having two or more cooling fluid line connections. Alternatively, an uncooled charging cable can also be connected to the charging plug using the coupling device. In this case, no cooling connector elements are provided, or the cooling connector elements are not connected and/or closed. In particular, the cooling connector element is provided for connection to cooling fluid lines that are provided for a cooling fluid return flow, i.e., a cooling fluid flow that flows away from the coupling device toward the high-performance charging cable. In particular, the energy connector element is provided for connection to cooling fluid lines that are provided for a cooling fluid inflow, i.e., a cooling fluid flow that flows from the high-performance charging cable to the coupling device and to the charging plug.

In this context, it is also proposed that the coupling device have a further check valve, which is arranged at least in part in a fluid line channel of the connector unit formed by the cooling connector element. This advantageously allows a high level of operational reliability to be achieved. Advantageously, cooling fluid can be prevented from leaking out of the high-performance charging cable and/or the coupling housing. In particular, the check valve of the fluid line channels formed by the cooling connector element is provided to automatically close the associated fluid line channel in a fluid-tight manner when the connector unit is separated. In particular, the check valve of the fluid line channels formed by the cooling connector element is designed to be at least substantially identical to the check valve of the energy connector elements, with the difference that it is arranged to permit an opposite flow direction. The permitted flow direction/opening direction of the check valve of the cooling connector element is reversed compared to the check valve of the energy connector element. The blocked flow direction/closure direction of the check valve of the cooling connector element is reversed compared to the check valve of the energy connector element. This check valve is also preferably arranged at least partially in a part of the coupling device, e.g., in a male (cooling) connector element of the connector unit, which is inserted into a receptacle, e.g., a plug-in receptacle of the charging cable connection unit of the charging plug, during connection. In particular, this check valve is arranged in the vicinity of a cooling fluid line opening of the respective (cooling) connector element. A further part of the additional check valve can be arranged in the charging plug. It is conceivable that the parts of the additional check valve are mounted simultaneously when the connector unit is connected to the charging cable connection unit.

In this context, it is proposed that the check valve and the additional check valve have different opening directions. This allows for a high degree of leak protection when the coupling device is removed from the high-performance charging cable. Furthermore, a particularly simple, leak-proof removal of the charging plug from the high-performance charging cable is enabled. In particular, the check valve of the cooling connector element allows cooling fluid to flow toward the high-performance charging cable. In particular, the check valve of the energy connector element allows cooling fluid to flow toward the charging plug/the outlet of the associated cooling fluid line. Preferably, all check valves have one or more closure elements that are automatically closed, e.g., by a spring force, when the respective fluid channels are depressurized. All check valves therefore prevent cooling fluid from flowing out of the high-performance charging cable when the coupling device is decoupled/the fluid lines are depressurized.

A particularly high degree of tightness can advantageously be achieved if the cooling connector element(s) and/or the energy connector element(s) each have at least one sealing element to form a Establish a fluid-tight fluid line contact with corresponding connector elements of the charging cable connection unit of the charging plug. The sealing elements can be designed, for example, as quad rings or O-rings surrounding the respective connector elements. The connector elements and the corresponding connector elements are intended to engage/be inserted into one another when connecting the coupling device, in particular the high-performance charging cable, to the charging plug.

It is additionally proposed that the connector unit additionally comprise at least one signal conductor connector element, which is provided at least for contacting one or more signal conductors of the high-performance charging cable. This advantageously makes it possible to achieve particularly simple and/or rapid assembly and/or disassembly of the high-performance charging cable with the charging plug, in particular by allowing several components of the high-performance charging cable to be connected to be connected and/or disassembled simultaneously/in a common assembly or disassembly step. The signal conductors can be provided for transmitting control signals between the external system and the charging station. The signal conductors can be provided for transmitting temperature measurement data from temperature sensors of the external system, the charging station, and/or the charging plug. The signal conductors can be provided for transmitting identifiers between the external system and the charging station, for example for authorizing a charging process or for automatically billing the charging process. Other, different information transmissions via the signal conductors are also possible.

If the power connector element, the additional power connector element, the cooling connector element, the grounding connector element, and/or the signal conductor connector element are configured as male connector elements, a plugging-in process can advantageously be facilitated. The connector elements preferably each protrude from the coupling housing in the axial direction and on a side of the coupling housing opposite the high-performance charging cable. The connector elements are each aligned parallel to one another. The connector elements can all be connected to the charging socket together in a single plugging-in movement. Alternatively, however, a reverse configuration would also be conceivable, in which the charging plug has the male part of the plug connection and the connector elements of the coupling device are female. Furthermore, a mixed form would also be conceivable, in which some of the connector elements of the coupling device are male while another part of the connector elements of the coupling device are female.

It is also proposed that several of the connector elements, in particular at least all the energy connector elements and at least all the cooling connector elements, preferably all the connector elements, of the connector unit be arranged and aligned such that they can be connected jointly, and preferably simultaneously, to the charging cable connection unit by means of a single linear coupling movement. This advantageously enables particularly simple, fast, and error-free assembly and/or disassembly of the high-performance charging cable and charging plug via the coupling device. The entire connector unit of the coupling device preferably forms a single, coherent connector geometry that can be plugged in all at once.

It is also proposed that the connector unit have a poka-yoke shape coding. This can advantageously simplify and/or make the assembly process safer. Rotated assembly can advantageously be prevented. In particular, the poka-yoke shape coding forms an anti-twist device that prevents incorrect/rotated insertion of the coupling device into the charging plug. The coupling device has a flattened portion, in particular on a radial outer circumference. The flattened portion forms at least part of the poka-yoke shape coding by only allowing insertion of the coupling device into a correspondingly shaped receptacle of the charging cable connection unit of the charging plug in one rotational orientation. This can also advantageously prevent damage to the connector elements due to incorrect insertion attempts.

The connector unit of the coupling device preferably has an asymmetrical arrangement of the connector elements. The arrangement of the connector elements, in particular, forms at least part of the poka-yoke shape coding by only allowing the connector elements of the connector unit to be inserted into the corresponding connector elements, in particular plug receptacles, of the charging cable connection unit of the charging plug in a single orientation.

Furthermore, it is proposed that the clutch housing has at least a first shell part and at least one second shell part, each of which is intended to partially, preferably completely, encompass the cable end of the high-performance charging cable in the circumferential direction. This advantageously enables simple reception and/or installation of the high-performance charging cable. The coupling housing advantageously has a simple construction. In particular, when assembled to one another, the two shell parts completely encompass the cable end of the high-performance charging cable in the circumferential direction. In particular, the two shell parts form a completely enclosed receiving space for the cable end of the high-performance charging cable. The two shell parts can be assembled to one another using screws or similar assembly elements. Alternatively or additionally, the two switching parts can also be welded or glued to one another or otherwise materially connected. The shell parts form part of the poka-yoke shape coding. One of the two shell parts, in particular the first shell part, preferably forms the flattened portion.

If the shell parts each have differently shaped separator and positioning webs for different cable components of the high-performance charging cable, this can advantageously enable simple and/or error-free installation of the coupling device to the cable end of the high-performance charging cable. This installation is often carried out in the field by external service personnel if necessary and should therefore be as clear and simple as possible. The separator and positioning webs of the first shell part are preferably intended for different cable components of the high-performance charging cable than the separator and positioning webs of the second shell part. The separator and positioning webs serve to separate the cable components of the high-performance charging cable, to position the cable components of the high-performance charging cable, and/or as an assembly aid for the arrangement of the cable components of the high-performance charging cable when installing the coupling device to the cable end.

It is further proposed that the coupling housing have at least one end cap part which covers the cable end in the axial direction and which has one or more openings for threading in one or more connector elements of the connector unit and/or which at least partially forms one or more of the connector elements of the connector unit. This advantageously makes it possible to achieve a stable connector geometry. This advantageously makes it possible to simplify and/or make operationally reliable a plug-in process in which the coupling device is plugged into the charging cable connection unit of the charging plug. The risk of jamming during plugging in can advantageously be reduced. The arrangements of the openings and/or the connector elements in or on the end cap part are preferably clearly defined, so that interchanging connections can advantageously be avoided.

Furthermore, it is proposed that the end cap part be fitted over the axial end regions of the two shell parts. This advantageously allows a high degree of fluid tightness to be achieved. In particular, the end cap part has locking elements which are intended to interact with corresponding locking elements of the shell parts. Preferably, the end cap part is clipped onto an axial end of the two shell parts after the shell parts have been connected to one another. In particular, the two shell parts are clicked/clipped in place under a part of the end cap part when the coupling housing is in the assembled state. The end cap part is connected to the shell parts in a fluid-tight manner. It is conceivable that an entire assembly formed by the two shell parts and the end cap part is cast after being mounted on the cable end of the high-performance charging cable and after being joined together.

Furthermore, it is proposed that the coupling device be provided in addition to connecting the high-performance charging cable to a cable outlet of the charging station. This advantageously allows for a high degree of flexibility. Advantageously, a very simple cable replacement, e.g., to adjust a cable length or for replacement in the event of damage, can be enabled. In particular, the charging station comprises a corresponding coupling device at the cable outlet, which is designed essentially identically to the charging cable connection unit of the charging plug, in particular having at least one corresponding plug connector unit that is at least essentially identical to the charging plug. In particular, the corresponding coupling device forms an adapter, which can be firmly connected to the charging station at the cable outlet of the charging station. In particular, the coupling device can be connected optionally to the charging plug or to the cable outlet of the electric vehicle charging station.

Furthermore, a charging cable system is proposed, comprising a high-performance charging cable with a cable end at which the coupling device is arranged. This advantageously allows for easy assembly and disassembly of the high-performance charging cable, e.g., to the charging plug and/or to the charging station. Maintenance can also be simplified.

It is also proposed that the high-performance charging cable have an additional cable end, at which a coupling device according to the invention is also arranged. This enables particularly simple assembly and/or disassembly of the entire high-performance charging cable.

Furthermore, a charging plug system with the coupling device and the charging plug is proposed. This advantageously simplifies the assembly and/or disassembly of charging plugs on high-performance charging cables, in particular fluid-cooled high-performance charging cables. The charging plug system can preferably be assembled, in particular quickly assembled, by plugging the coupling housing of the coupling device into the charging cable connection unit of the charging plug. The charging plug system can preferably be disassembled, in particular quickly disassembled, by unplugging the coupling housing of the coupling device from the charging cable connection unit of the charging plug. The charging cable connection unit preferably has an assembly guide. The assembly guide is designed as a radially at least partially enclosed receptacle for the coupling housing, along the axial extent of which the coupling housing is to be moved during assembly. At an inner end of the assembly guide, a connector unit (connector socket) corresponding to the connector unit of the coupling device and having the corresponding connector elements, in particular plug receptacles, is arranged. The mounting guide has an inner shape that is adapted to the outer shape of the coupling housing. The mounting guide thus enables anti-twisting protection through the poka-yoke shape coding of the connector unit. The arrangement of the corresponding connector elements of the charging cable connection unit corresponds to the arrangement of the connector elements of the coupling device.

Furthermore, a charging device with the charging plug system and the high-performance charging cable is proposed. This advantageously enables particularly simple charging plug replacement, particularly simple charging plug maintenance, and/or particularly simple charging plug repair.

Furthermore, a modular system for producing different charging plug systems and/or different charging devices is proposed. The modular system comprises a plurality of different coupling housings and/or a plurality of different charging plugs, wherein the coupling housings of the modular system are provided for accommodating different high-performance charging cables, in particular high-performance charging cables of different dimensions, and wherein the coupling housings of the modular system are all compatible with at least one of the charging plugs of the modular system, and preferably with all charging plugs of the modular system, and/or wherein the charging plugs of the modular system are provided for coupling with different charging sockets, in particular charging sockets with different socket types, and wherein the charging plugs of the modular system are all compatible with at least one of the coupling housings of the modular system, and preferably with all coupling housings of the modular system. This advantageously allows a high degree of flexibility to be achieved. Advantageously, existing charging devices/charging stations can be easily adapted, e.g. when switching to other, newer plug types.

Furthermore, an electric vehicle charging station with the charging cable system and with an electrical energy source, for example a charging column, is proposed. This advantageously enables particularly simple charging station maintenance and/or particularly simple charging station repair. The electrical energy source, in particular, provides the charging energy, which can be tapped via the charging plug and/or transmitted via the high-performance charging cable. The charging station is preferably a (direct current) rapid charging station for electric vehicles. The charging station is intended, in particular, to provide peak charging powers above 100 kW, advantageously above 300 kW, preferably above 500 kW, and particularly preferably above 1 MW.

Furthermore, a method for assembling and/or disassembling the charging plug system and/or the electric vehicle charging station, in particular during an installation process, a deinstallation process, a conversion process, a repair process and/or a maintenance process, is proposed. In the method, the coupling device, in particular a quick-coupling device, which can be connected or is connected to the cable end of the high-performance charging cable, is mounted to the charging plug and/or to a cable outlet of the electric vehicle charging station by a positive and/or force-fitting insertion of plug connector elements of the plug connector unit into corresponding plug connector elements of the respective charging cable connection unit (of the charging plug or the electric vehicle charging station). Alternatively or additionally, in the method, the coupling device, in particular a quick-coupling device, which can be connected or is connected to one of the cable ends of the high-performance charging cable, is mounted by a The coupling device is removed from the charging plug and/or the cable outlet of the electric vehicle charging station, whereby the positive and/or non-positive connection of the plug-in connector elements of the plug-in connector unit with the corresponding plug-in connector elements of the respective charging cable connection unit (of the charging plug or the electric vehicle charging station) is released. This advantageously simplifies the assembly and/or disassembly of charging plugs on high-performance charging cables, in particular fluid-cooled high-performance charging cables. Advantageously, service work such as the replacement, repair, and/or maintenance of a charging plug and/or a high-performance charging cable can be significantly accelerated.

The coupling device according to the invention, the charging plug system according to the invention, the charging device according to the invention, the modular system according to the invention, the charging station according to the invention, and the method according to the invention are not intended to be limited to the application and embodiment described above. In particular, the coupling device according to the invention, the charging plug system according to the invention, the charging device according to the invention, the modular system according to the invention, the charging station according to the invention, and the method according to the invention may have a number of individual elements, components, method steps, and units that differs from the number stated herein to fulfill a function described herein.

Drawings

Further advantages will become apparent from the following description of the drawings. The drawings illustrate an exemplary embodiment of the invention. The drawings, the description, and the claims contain numerous features in combination. Those skilled in the art will also expediently consider the features individually and combine them into useful further combinations.

• 1 eine schematische Darstellung eines als Elektrofahrzeug ausgebildeten externen Systems und einer Elektrofahrzeug-Ladestation mit einer Ladevorrichtung
• 2 eine perspektivische Darstellung der Ladevorrichtung mit einem einen Ladestecker und eine Kupplungsvorrichtung umfassenden montierten Ladestecker-System und mit einem Hochleistungs-Ladekabel,
• 3a eine perspektivische Darstellung des Hochleistungs-Ladekabels und des Ladestecker-Systems in einem demontierten Zustand,
• 3b eine perspektivische Darstellung des Hochleistungs-Ladekabels und eines Teils der Elektrofahrzeug-Ladestation in einem demontierten Zustand,
• 4 eine perspektivische Darstellung einer korrespondierenden Steckverbindereinheit des Ladesteckers,
• 5 eine perspektivische Darstellung der Kupplungsvorrichtung mit der Steckverbindereinheit und mit einem Kupplungsgehäuse,
• 6 eine schematische perspektivische Darstellung eines Kabelendes des Hochleistungs-Ladekabels mit dessen Komponenten,
• 7 eine perspektivische Darstellung eines ersten Schalenteils des Kupplungsgehäuses,
• 8 eine perspektivische Darstellung eines zweiten Schalenteils des Kupplungsgehäuses,
• 9 eine schematische Schnittdarstellung der Kupplungsvorrichtung und des Hochleistungs-Ladekabels,
• 10 eine perspektivische Darstellung eines Energie-Steckverbinderelements der Steckverbindereinheit mit einer Stützhülse,
• 11 eine schematische Darstellung eines Baukastens zur Herstellung von unterschiedlichen Ladestecker-Systemen und/oder von unterschiedlichen Ladevorrichtungen und
• 12 ein schematisches Ablaufdiagramm eines Verfahrens zu einer Montage und/oder Demontage der Ladevorrichtung und/oder der Elektrofahrzeug-Ladestation.

They show:

• 1 a schematic representation of an external system designed as an electric vehicle and an electric vehicle charging station with a charging device
• 2 a perspective view of the charging device with a charging plug system comprising a charging plug and a coupling device and with a high-performance charging cable,
• 3a a perspective view of the high-performance charging cable and the charging plug system in a disassembled state,
• 3b a perspective view of the high-performance charging cable and part of the electric vehicle charging station in a disassembled state,
• 4 a perspective view of a corresponding connector unit of the charging plug,
• 5 a perspective view of the coupling device with the connector unit and with a coupling housing,
• 6 a schematic perspective view of one cable end of the high-performance charging cable with its components,
• 7 a perspective view of a first shell part of the clutch housing,
• 8 a perspective view of a second shell part of the clutch housing,
• 9 a schematic sectional view of the coupling device and the high-performance charging cable,
• 10 a perspective view of an energy connector element of the connector unit with a support sleeve,
• 11 a schematic representation of a kit for the production of different charging plug systems and/or different charging devices and
• 12 a schematic flow diagram of a method for assembling and/or disassembling the charging device and/or the electric vehicle charging station.

Description of the embodiment

The 1 shows a schematic diagram of a charging station. The charging station is provided for electrically charging a rechargeable battery of an external system 18. The external system 18 can be, for example, an electric vehicle. The external system 18 has a charging socket 16. The charging station is designed as an electric vehicle charging station 12. The electric vehicle charging station 12 has an energy source 108. The energy source 108 provides the electrical charging energy. The energy source 108 is designed as a charging column. The charging column is, for example, a direct current rapid charging column for electric vehicles. The electric vehicle charging station 12 has a charging device 104. The electric vehicle charging station 12 has a charging cable system 146. The electric vehicle charging station 12 comprises an active cooling device 112 for cooling down a cooling fluid. The charging device 104 comprises a high-performance charging cable 10. The charging cable system 146 comprises the high-performance charging cable 10. The electric vehicle charging station 12 has a cable outlet 148 The cable outlet 148 is provided for mounting the high-performance charging cable 10. The high-performance charging cable 10 is designed, for example, to conduct direct current in the three-digit kilowatt range or in the megawatt range. The high-performance charging cable 10 is internally fluid-cooled. The cooling fluid cooled by the cooling device 112 is guided (in two opposite directions) through the high-performance charging cable 10. The charging device 104 has a charging plug system 100. The charging plug system 100 comprises a charging plug 14. The charging plug 14 is internally fluid-cooled. In the charging plug 14, the cooling fluid originating from the cooling device 112 is redirected and guided back to the cooling device 112.

The charging plug 14 is provided for establishing an energy-transmitting connection between the high-performance charging cable 10 and the charging socket 16 of the external system 18. The charging plug 14 is provided for insertion into the charging socket 16 of the external system 18. The charging plug system 100 has a coupling device 102. The coupling device 102 is provided for connecting the high-performance charging cable 10 to the charging plug 14. The 2 shows a schematic perspective view of the assembled charging plug system 100, wherein the charging plug 14 and the coupling device 102 are connected to each other. 3a shows a schematic perspective view of the disassembled charging plug system 100, wherein the charging plug 14 and the coupling device 102 are separated from each other. The coupling device 102 is provided in addition to connecting the high-performance charging cable 10 to the cable outlet 148 of the electric vehicle charging station 12. For this purpose, the charging cable system 146 has a high-performance charging cable 10, which is provided with an identical coupling device 102 at each of the two cable ends 26, 144. The 3b shows a schematic perspective view of the disassembled charging cable system 146, wherein the cable outlet 148 and the coupling device 102 are separated from each other. 4 shows only the charging plug 14 in a schematic view and the 5 shows only the coupling device 102 in a schematic view.

The charging plug 14 comprises a plug geometry 114 for coupling with the charging socket 16 of the external system 18. The 2 The connector geometry 114 shown is an example of a CCS connector geometry. However, other connector geometries are also conceivable. The charging connector 14 has a handle element 116 that simplifies manual handling. The charging connector 14 has a charging cable connection unit 42 (see in particular 4 ). The charging cable connection unit 42 enables and establishes an energy-transmitting connection between the charging plug 14 and the high-performance charging cable 10.

The coupling device 102 forms a quick-coupling device. The quick-coupling device can be connected to the charging plug 14 with a single movement and/or separated from the charging plug 14 with a single movement. The coupling device 102 has a plug-in connector unit 40. The plug-in connector unit 40 is provided for a positive and/or force-fitting insertion into the charging cable connection unit 42 of the charging plug 14. The coupling device 102 has a coupling housing 20. The coupling housing 20 is provided for a fluid-tight reception of a cable end 26, 144 of the high-performance charging cable 10. The plug-in connector unit 40 and in particular the coupling housing 20 have a poka-yoke shape coding (see va 5 ). The charging plug 14 forms an assembly guide 110. The coupling housing 20 and the connector unit 40 are inserted/pushed into the assembly guide 110 for mounting the high-performance charging cable 10 to the charging plug 14. The coupling housing 20 and the connector unit 40 are pulled out of the assembly guide 110 for disassembling the high-performance charging cable 10 from the charging plug 14. The assembly guide 110 has an inner shape that corresponds to an outer shape of the coupling housing 20 and only allows the coupling housing 20 to be inserted into the assembly guide 110 in a single rotational position about a central axis of the coupling housing 20.

A free cable end 26 of the high-performance charging cable 10 and the components of the high-performance charging cable 10 are shown schematically in the 6 shown. The high-performance charging cable 10 comprises an outer sheath 120. All components of the high-performance charging cable 10 are arranged within the outer sheath 120. The components of the high-performance charging cable 10 are twisted together within the outer sheath 120. The high-performance charging cable 10 comprises a power line 24. The high-performance charging cable 10 comprises a first cooling fluid line 22. The first cooling fluid line 22 runs within an identical sheath 118 as the power line 24. The first cooling fluid line 22 runs centrally inside conductor strands 122 of the power line 24. The power line 24 forms a cavity 62, which in turn forms the first cooling fluid line 22. The cooling fluid is guided through the cavity 62. The high-performance charging cable 10 comprises a further power line 38. The high-performance charging cable 10 comprises a second cooling fluid line 28. The further power line 38 is at least substantially identical to the power line 24 and is integral with the second cooling fluid line 28. The high-performance charging cable 10 comprises a third cooling fluid line 30. The high-performance charging cable 10 comprises a fourth cooling fluid line 32. The high-performance charging cable 10 comprises a fifth cooling fluid line 34. The high-performance charging cable 10 comprises a sixth cooling fluid line 36. Configurations of the high-performance charging cable 10 with more or fewer than six cooling fluid lines 22, 28, 30, 32, 34, 36, for example with four cooling fluid lines 22, 28, 30, 32 (two integrated with the power lines 24, 38 and two separate) are also conceivable. The third to sixth cooling fluid lines 30, 32, 34, 36 are each formed separately from the power lines 24, 38. The third to sixth cooling fluid lines 30, 32, 34, 36 are each free of electrical conduction elements, such as conductor strands 122. The high-performance charging cable 10 includes a grounding conductor 68. The high-performance charging cable 10 includes a signal conductor 84.

The clutch housing 20 has a first shell part 86. The first shell part 86 is shown in a schematic perspective view in the 7 The clutch housing 20 has a second shell part 88. The second shell part 88 is shown in a schematic perspective view in the 8 shown. The two shell parts 86, 88 are each intended to partially encompass the cable end 26 of the high-performance charging cable 10 in the circumferential direction. The two shell parts 86, 88 are each intended to completely encompass the cable end 26 of the high-performance charging cable 10 in the circumferential direction when joined together. The shell parts 86, 88 each have differently shaped separator and positioning webs 90, 92. The differently shaped separator and positioning webs 90, 92 are each provided for positioning different line components of the high-performance charging cable 10 within the coupling housing 20. The separator and positioning web 90 of the first shell part 86 is provided for positioning the grounding conductor 68. The separator and positioning web 90 of the first shell part 86 is provided for positioning two of the cooling fluid lines 30, 32, 34, 36 formed separately from the power lines 24, 38. The separator and positioning web 92 of the second shell part 88 is provided for positioning the power line 24. The separator and positioning web 92 of the second shell part 88 is provided for positioning the further power line 38. Returning to the 3a It can be seen that the coupling housing 20 has an end cap part 94. The end cap part 94 covers the cable end 26 in an axial direction 96 of the coupling housing 20. The end cap part 94 is mounted by slipping it over axial end regions of the two joined shell parts 86, 88. The coupling housing 20 has a further end cap part 124. The further end cap part 124 is arranged at an end of the coupling housing 20 opposite the end cap part 94 in the axial direction 96. The further end cap part 124 forms a transition to the high-performance charging cable 10 emerging from the coupling housing 20. The further end cap part 124 comprises an opening 126 through which the high-performance charging cable 10 can emerge from an interior of the coupling housing 20. A size of the opening 126 corresponds approximately to an outer diameter of the outer sheath 120 of the high-performance charging cable 10. The individual parts of the coupling housing 20 are each injection-molded plastic parts.

The schematic sectional view of the coupling device 102 from the 9 It can also be seen that the coupling housing 20 comprises an annular seal 128, which is intended to seal the further end cap part 124 to the two shell parts 86, 88. Furthermore, the coupling housing 20 comprises a positioning aid element 130 formed as a separate injection-molded part. The positioning aid element 130 is intended to optimally align the shell parts 86, 88 with one another during assembly of the coupling housing 20. The positioning aid element 130 is designed such that it cannot be rotated in the assembled state and that it only fits into the two shell parts 86, 88 in a single position.

In the 9 It is also shown that the connector unit 40 continues the cooling fluid lines 22, 28, 30, 32, 34, 36 and the power lines 24, 38 of the cable end 26 of the high-performance charging cable 10. In connection with the following explanations, reference is again made to the 3a and 5 The connector unit 40 has a power connector element 44. The power connector element 44 continues the power line 24 of the high-performance charging cable 10. At the same time, the power connector element 44 also continues the first cooling fluid line 22 of the high-performance charging cable 10. The connector unit 40 additionally has a further power connector element 46. The further power connector element 46 is provided for a common continuation of the further power line 38 of the high-performance charging cable 10 and the second cooling fluid line 28 of the high-performance charging cable 10. The power connector element 44 and in particular also the further power connector element 46 each comprise a support sleeve 58. The power connector element 44 with the support sleeve 58 is also shown schematically in the 10 The support sleeve 58 is inserted into the cavity 62 of the respective power line 24, 38. The support sleeve 58 is intended to, when connecting the respective power connector elements elements 44, 46 with the respective power line 24, 38 by compressing the cavity 62, for example by crimping on a crimpable connection element 64 (see 9 and 10 ) of the respective power connector element 44, 46 onto the respective power line 24, 38. The coupling device 102 also has silicone seals 142. The silicone seals 142 are provided for sealing crimp connections, particularly in cases of suboptimal crimping. The silicone seals 142 are provided for sealing the connection element 64. The silicone seals 142 are applied to the respective power lines 24, 38 and/or cooling fluid lines 22, 28, 30, 32, 34, 36 before the connection elements 64 are crimped.

In addition to the power connector elements 44, 46, the connector unit 40 has a first cooling connector element 70 and in particular a second cooling connector element 72. The cooling connector elements 70, 72 are each free of electrical contacts. The cooling connector elements 70, 72 are each provided for a continuation of at least one of the cooling fluid lines 30, 32, 34, 36 of the high-performance charging cable 10, which are separated from the power lines 24, 38. The cooling connector elements 70, 72 are each provided for a continuation of exactly two of the cooling fluid lines 30, 32, 34, 36 of the high-performance charging cable 10, which are separated from the power lines 24, 38. The coupling device 102 has Y-connectors 132. The Y-connectors 132 are provided for joining two of the cooling fluid lines 30, 32, 34, 36 of the high-performance charging cable 10, which are separated from the power lines 24, 38. The joined cooling fluid lines 30, 32, 34, 36 are then routed via the Y-connector 132 to the respective cooling connector element 72. The Y-connectors 132 are Y-connectors.

The connector unit 40 has a grounding connector element 66. The grounding connector element 66 is provided for contacting the grounding conductor 68 of the high-performance charging cable 10. The grounding connector element 66 is provided for extending the grounding conductor 68 of the high-performance charging cable 10 to the charging plug 14. The connector unit 40 has a signal conductor connector element 82. The signal conductor connector element 82 is provided for contacting the signal conductor 84 of the high-performance charging cable 10. The signal conductor connector element 82 is provided for extending the signal conductor 84 of the high-performance charging cable 10 to the charging plug 14. The power connector element 44 is designed as a male connector element. The further power connector element 46 is designed as a male connector element. The cooling connector element 70 is designed as a male connector element. The additional cooling connector element 72 is designed as a male connector element. The grounding connector element 66 is designed as a male connector element. The signal conductor connector element 82 is designed as a male connector element. All power connector elements 44, 46 and at least all cooling connector elements 70, 72, preferably all connector elements 44, 46, 66, 70, 72, 82, of the connector unit 40 are arranged and aligned such that they can be connected jointly and approximately simultaneously to the charging cable connection unit 42 by means of a single linear coupling movement. The end cap part 94 comprises openings 98, each of which is provided for threading in precisely one of the connector elements 44, 46, 66, 70, 72, 82 of the connector unit 40. Each of the connector elements 44, 46, 66, 70, 72, 82 of the connector unit 40 has a dedicated opening 98 in the end cap part 94. As an alternative to the openings 98, it is also conceivable for the end cap part 94 to directly form the connector elements 44, 46, 66, 70, 72, 82 of the connector unit 40.

The charging cable connection unit 42 of the charging plug 14 has a connector unit 134 corresponding to the connector unit 40 (see va 4 ). The corresponding connector unit 134 comprises exactly one corresponding connector element 54, 56 for each of the connector elements 44, 46, 66, 70, 72, 82 of the connector unit 134. The corresponding connector elements 54, 56 are each designed as female connector elements. The connector elements 44, 46, 66, 70, 72, 82 of the connector unit 134 are plugged into the corresponding connector elements 54, 56 of the corresponding connector unit 134 to connect the high-performance charging cable 10 to the charging plug 14. The cooling connector elements 70, 72 and the cooling fluid-carrying energy connector elements 44, 46 each have one or more sealing elements 140, which are provided for establishing a fluid-tight fluid line contact with the associated corresponding connector elements 54, 56 of the corresponding connector unit 134 of the charging cable connection unit 42 of the charging plug 14. The sealing elements 140 are designed as quadrings, which are each slipped over the male cooling fluid-carrying connector elements 44, 46, 70, 72. The energy connector elements 44, 46 each have at least one electrical contact element 60, which is provided for establishing an intimate Power line contact with the current-carrying corresponding connector elements 54 of the corresponding connector unit 134 of the charging cable connection unit 42 of the charging plug 14 is provided. At the cable outlet 148 of the electric vehicle charging station 12, at least one charging cable connection unit (not shown) substantially identical to the charging cable connection unit 42 of the charging plug 14 is arranged. The coupling device 102 can be connected to the charging cable connection unit at the cable outlet 148 of the electric vehicle charging station 12, just as it can be connected to the charging cable connection unit 42 of the charging plug 14.

The coupling device 102 has a check valve 48 (see the sectional drawing of the 9 ). The energy connector element 44 forms a fluid line channel 50 of the connector unit 40. The further energy connector element 46 forms a further fluid line channel (not shown) of the connector unit 40. The check valve 48 is arranged in the fluid line channel 50 of the energy connector element 44. Preferably, an (identical) check valve 48 is also arranged in the further fluid line channel of the further energy connector element 46. The coupling device has a further check valve 74. The cooling connector element 70 forms a fluid line channel 76. The further check valve 74 is arranged in the fluid line channel 76 of the cooling connector element 70. In addition, fluid line channels 76 are also formed in all further cooling connector elements 72, in which (identical) further check valves 74 are also arranged. The check valve 48(s) and the further check valve 74(s) have different opening directions 78, 80. When the charging plug system 100 is assembled, the check valve 48 allows cooling fluid to flow from the high-performance charging cable 10 into the charging plug 14, and when the charging plug system 100 is not assembled, it blocks cooling fluid from the high-performance charging cable 10. When the charging plug system 100 is assembled, the further check valve 74 allows cooling fluid to flow from the charging plug 14 into the high-performance charging cable 10, and when the charging plug system 100 is not assembled, it blocks cooling fluid from the high-performance charging cable 10.

The 11 schematically shows a kit 106 for producing different charging plug systems 100 and/or different charging devices 104. The kit 106 comprises a plurality of different coupling housings 20, 20'. The different coupling housings 20, 20' of the kit 106 are provided at least for accommodating differently dimensioned high-performance charging cables 10, 10'. The different coupling housings 20, 20' have different sizes of openings 126, 126' for this purpose. The kit 106 comprises a plurality of different charging plugs 14, 14'. The different charging plugs 14, 14' of the kit 106 are each provided for coupling to different charging sockets 16, in particular to charging sockets 16 that have different socket types (e.g. CCS and NACS, etc.). The different charging plugs 14, 14' of the kit 106 form different plug geometries 114, 114'.

The various coupling housings 20, 20' of the modular system 106 can all be combined in a compatible manner with at least one of the charging plugs 14, 14' of the modular system 106, and preferably with all charging plugs 14, 14' of the modular system 106. The various charging plugs 14, 14' of the modular system 106 can all be combined in a compatible manner with at least one of the coupling housings 20, 20' of the modular system 106, and preferably with all coupling housings 20, 20' of the modular system 106.

The 12 shows a schematic flow diagram of a method for assembling and/or disassembling the charging device 104. In at least one method step 136, the coupling device 102 connected to the cable end 26 of the high-performance charging cable 10 is disassembled by unplugging/pulling the coupling device 102 from the charging plug 14. In method step 136, a positive and/or non-positive plug connection of the plug connector elements 44, 46, 66, 70, 72, 82 of the plug connector unit 40 with the corresponding plug connector elements 54, 56 of the corresponding plug connector unit 134 of the charging cable connection unit 42 of the charging plug 14 is released. In method step 136, the coupling housing 20 with the plug connector unit 40 is removed from the charging plug 14 along a direction of movement predetermined by the assembly guide 110. In at least one method step 138, the coupling device 102 connected to the cable end 26 of the high-performance charging cable 10 is mounted to the charging plug 14 by positively and/or force-fitting insertion of the plug-in connector elements 44, 46, 66, 70, 72, 82 of the plug-in connector unit 40 into corresponding plug-in connector elements 54, 56 of the corresponding plug-in connector unit 134 of the charging cable connection unit 42 of the charging plug 14. In method step 138, a positively and/or force-fitting plug connection of the plug-in connector elements 44, 46, 66, 70, 72, 82 of the plug-in connector unit 40 with the corresponding plug-in connector elements 54, 56 the corresponding connector unit 134 of the charging cable connection unit 42 of the charging plug 14. In method step 138, the coupling housing 20 with the connector unit 40 is moved toward the corresponding connector unit 134 along a direction of movement predetermined by the assembly guide 110. In method steps 136, 138 or in further method steps at a cable end 144 of the high-performance charging cable 10 opposite the cable end 26, the coupling device 102 could alternatively be connected to or disassembled from a charging cable connection unit of the cable outlet 148 of the electric vehicle charging station 12. The process is at least substantially identical to that described above.

Reference symbol

10

High-performance charging cable

12

Charging station

14

Charging plug

16

Charging socket

18

External system

20

clutch housing

22

Cooling fluid line

24

power line

26

cable end

28

Cooling fluid line

30

Cooling fluid line

32

Cooling fluid line

34

Cooling fluid line

36

Cooling fluid line

38

power line

40

Connector unit

42

Charging cable connection unit

44

Energy connector element

46

Additional energy connector element

48

Check valve

50

Fluid line channel

54

Corresponding connector element

56

Additional corresponding connector element

58

Support sleeve

60

Contact element

62

cavity

64

connecting element

66

Grounding connector element

68

Grounding conductor

70

Cooling connector element

72

Cooling connector element

74

Additional check valve

76

Fluid line channel

78

Opening direction

80

Opening direction

82

Signal conductor connector element

84

Signal conductor

86

First shell part

88

Second shell part

90

Separator and positioning web

92

Separator and positioning web

94

End cap part

96

axial direction

98

opening

100

Charging plug system

102

Coupling device

104

Charging device

106

Construction kit

108

Energy source

110

Assembly guide

112

Cooling device

114

Connector geometry

116

Handle element

118

Sheathing

120

Outer shell

122

stranded conductor

124

End cap part

126

opening

128

Ring seal

130

Positioning aid element

132

Y-connector

134

Corresponding connector unit

136

Process step

138

Process step

140

Sealing element

142

Silicone seal

144

cable end

146

Charging cable system

148

Cable outlet

Claims (28)

Coupling device (102), in particular a quick-coupling device, at least for connecting a, preferably fluid-cooled, high-performance charging cable (10), for example of an electric vehicle charging station (12), to a charging plug (14), which is provided for establishing an energy-transmitting connection of the high-performance charging cable (10) to a charging socket (16) of an external system (18), for example a charging socket (16) of an electric vehicle, comprising a coupling housing (20), which is provided for a preferably fluid-tight reception of a cable end (26) of the high-performance charging cable (10), characterized by a plug-in connector unit (40) which continues at least one cooling fluid line (22, 28, 30, 32, 34, 36) and/or at least one power line (24, 38) of the cable end (26) of the high-performance charging cable (10), which is provided for a positive and/or non-positive insertion into a charging cable connection unit (42) of the charging plug (14). Coupling device (102) according to Claim 1 , characterized in that the plug connector unit (40) has at least one energy plug connector element (44) which is provided for a continuation of exactly one power line (24) of the high-performance charging cable (10). Coupling device (102) according to Claim 2 , characterized in that the at least one energy connector element (44) is provided in addition to a continuation of exactly one cooling fluid line (22) of the high-performance charging cable (10). Coupling device (102) according to Claim 3 , characterized in that the plug-in connector unit (40) additionally has at least one further energy plug-in connector element (46) which is provided for a common continuation of exactly one further power line (38) of the high-performance charging cable (10) and exactly one further cooling fluid line (28) of the high-performance charging cable (10). Coupling device (102) according to Claim 3 or 4 , characterized by a check valve (48) which is arranged at least in part in a fluid line channel (50) of the connector unit (40) formed by the energy connector element (44) and/or in a further fluid line channel of the connector unit (40) formed by the further energy connector element (46). Coupling device (102) according to one of the Claims 2 until 5 , characterized in that the energy plug connector element(s) (44, 46) each have at least one electrical contact element (60) for establishing an intimate power line contact with corresponding plug connector elements (54) of the charging cable connection unit (42) of the charging plug (14). Coupling device (102) according to one of the Claims 2 until 6 , characterized in that at least the energy connector element (44) comprises a support sleeve (58) which is intended to be introduced into an axial cavity (62) of the power line (24) when connected to the power line (24) of the high-performance charging cable (10) and to counteract a compression of this cavity (62) when connecting the at least one energy connector element (44) to the power line (24), in particular by crimping a crimpable connection element (64) of the energy connector element (44) onto the power line (24). Coupling device (102) according to one of the Claims 2 until 7 , characterized in that the plug connector unit (40) additionally has at least one grounding plug connector element (66) which is provided at least for contacting a grounding conductor (68) of the high-performance charging cable (10). Coupling device (102) according to one of the Claims 2 until 8 , characterized in that the plug connector unit (40) additionally has at least one cooling plug connector element (70) which is free of electrical contacts and which is provided for a continuation of at least one cooling fluid line (32) of the high-performance charging cable (10). Coupling device (102) according to Claim 9 , characterized in that the at least one cooling connector element (72) is provided for a continuation of at least one further cooling fluid line (34) of the high-performance charging cable (10), which is different from the cooling fluid line (32). Coupling device (102) according to Claim 9 or 10 , characterized by a further check valve (74) which is arranged at least in part in a fluid line channel (76) of the connector unit (40) formed by the cooling connector element (72). Coupling device (102) at least according to the Claims 5 and 11 , characterized in that the check valve (48) and the further check valve (74) have different opening directions (78, 80). Coupling device (102) according to at least one of the Claims 2 until 12 , characterized in that the cooling connector element(s) (70, 72) and/or the energy connector element(s) (44, 46) each have at least one sealing element (140) for producing a fluid-tight fluid line contact with corresponding connector elements (54, 56) of the charging cable connection unit (42) of the charging plug (14). Coupling device (102) according to one of the Claims 2 until 13 , characterized in that the plug connector unit (40) additionally has at least one signal conductor plug connector element (82) which is provided at least for contacting one or more signal conductors (84) of the high-performance charging cable (10). Coupling device (102) according to one or more of the Claims 2 until 14 , characterized in that the power connector element (44), the further power connector element (46), the cooling connector element (70, 72), the grounding connector element (66) and/or the signal conductor connector element (82) is designed as a male connector element. Coupling device (102) according to one of the preceding claims, characterized in that several of the plug-in connector elements (44, 46, 66, 70, 72, 82), in particular at least all of the energy plug-in connector elements (44, 46) and at least all of the cooling plug-in connector elements (70, 72), preferably all of the plug-in connector elements (44, 46, 66, 70, 72, 82), of the plug-in connector unit (40) are arranged and aligned such that they can be connected jointly, and preferably simultaneously, to the charging cable connection unit (42) by means of a single linear coupling movement. Coupling device (102) according to one of the preceding claims, characterized in that the plug-in connector unit (40) has a poka-yoke shape coding. Coupling device (102) according to one of the preceding claims, characterized in that the coupling housing (20) comprises at least a first shell part (86) and at least a second shell part (88), which are each provided to partially encompass the cable end (26) of the high-performance charging cable (10) in the circumferential direction. Coupling device (102) according to Claim 18 , characterized in that the shell parts (86, 88) each have differently shaped separator and positioning webs (90, 92) for different line components (22, 24, 28, 30, 32, 34, 36, 38, 68, 84) of the high-performance charging cable (10). Coupling device (102) according to one of the preceding claims, characterized in that the coupling housing (20) has at least one end cap part (94) which covers the cable end (26) in the axial direction (96) and which has one or more openings (98) for a respective threading of one or more connector elements (44, 46, 66, 70, 72, 82) of the connector unit (40) and/or which at least partially forms one or more of the connector elements (44, 46, 66, 70, 72, 82) of the connector unit (40). Coupling device (102) at least according to the Claims 18 and 20 , characterized in that the end cap part (94) is mounted over axial end regions of the two shell parts (86, 88). Coupling device (102) according to one of the preceding claims, characterized in that the coupling device (102) is additionally provided for connecting the high-performance charging cable (10) to a cable outlet (148) of the electric vehicle charging station (12). Charging cable system (146) comprising a high-performance charging cable (10) with a cable end (26) on which a coupling device (102) according to one of the preceding claims is arranged. Charging cable system (146) according to Claim 23 , characterized in that the high-performance charging cable (10) has a further cable end (144) to which a coupling device (102) according to one of the Claims 1 until 21 is arranged. Charging plug system (100) with a coupling device (102) according to one of the Claims 1 until 22 and with the charging plug (14). Modular kit (106) for the production of different charging plug systems (100) according to Claim 25 , with a plurality of different coupling housings (20, 20') and/or with a plurality of different charging plugs (14, 14'), wherein the coupling housings (20, 20') of the modular system (106) are provided for receiving different high-performance charging cables (10, 10'), in particular differently dimensioned high-performance charging cables (10, 10'), and wherein the coupling housings (20, 20') of the modular system (106) are all compatible with at least one of the charging plugs (14, 14') of the modular system (106), and preferably with all charging plugs (14, 14') of the modular system (106), and/or wherein the charging plugs (14, 14') of the modular system (106) are provided for coupling with different charging sockets (16), in particular charging sockets (16) with different socket types, and wherein the charging plugs (14, 14') of the modular system (106) are all compatible with at least one of the coupling housings (20, 20') of the modular system (106), and preferably with all coupling housings (20, 20') of the modular system (106), can be combined in a compatible manner. Electric vehicle charging station (12) with the charging cable system (146) according to Claim 23 or 24 , and with an energy source (108), for example a charging station. Method for assembling and/or disassembling a charging plug system (100) according to the Claim 25 and/or an electric vehicle charging station (12) according to the Claim 27 , in particular in the context of an installation process, a deinstallation process, a conversion process, a repair process and/or a maintenance process, characterized in that the coupling device (102), in particular a quick-coupling device, which can be connected or is connected to a cable end (26, 144) of the high-performance charging cable (10), is mounted to the charging plug (14) and/or to a cable outlet (148) of the electric vehicle charging station (12) by a positive and/or force-fitting insertion of plug connector elements (44, 46, 66, 70, 72, 82) of the plug connector unit (40) into corresponding plug connector elements (54, 56) of the respective charging cable connection unit (42), and/or that the coupling device (102), in particular Quick coupling device, is dismantled by unplugging the coupling device (102) from the charging plug (14) and/or from the cable outlet (148) of the electric vehicle charging station (12), wherein the positive and/or non-positive plug connection of the plug connector elements (44, 46, 66, 70, 72, 82) of the plug connector unit (40) with the corresponding plug connector elements (54, 56) of the respective charging cable connection unit (42) is released.