METHOD

TECHNICAL FIELD

The disclosure relates to a first electrical connector, a second electrical connector and a respective method.

BACKGROUND

Although applicable to any electrical connector, the present disclosure will mainly be de scribed in conjunction with electrical connectors for charging stations and charging ca bles of electrical vehicles.

Electrical vehicles are usually equipped with batteries that provide the electrical power to drive the electrical vehicle. These batteries may be charged via an external charging station.

Specific charging cables are usually used to couple an electrical vehicle to a charging station for charging the internal batteries of the electrical vehicle. Depending for exam ple on the diameter of the single wires in the charging cable, the respective charging ca ble may have a predetermined current carrying capacity that may not be exceeded while charging a vehicle. Complex systems are available that measure the resistance of a charging cable prior to initiating the charging of the vehicle to determine the current carrying capacity of the charging cable.

Accordingly, there is a need for easily determining the current carrying capacity of a charging cable.

SUMMARY

The above stated problem is solved by the features of the independent claims. It is un derstood, that independent claims of a claim category may be formed in analogy to the dependent claims of another claim category. Accordingly, it is provided:

A first electrical connector for coupling to a second electrical connector, the first electri cal connector comprising a first outer enclosure that surrounds a first contact space and comprises an opening on a front side of the first electrical connector in longitudinal di rection of the first contact space, a number of first electrical contacts arranged in the first contact space and configured to couple to second electrical contacts of the second electrical connector, and a light generation device arranged in the first contact space and configured to emitt light of a predetermined type.

Further, it is provided:

A second electrical connector for coupling to a first electrical connector, the second electrical connector comprising a second outer enclosure that surrounds a second con tact space and comprises an opening on a front side of the second electrical connector in longitudinal direction of the second contact space, a number of second electrical con tacts arranged in the second contact space and configured to couple to first electrical contacts of the first electrical connector, a light sensor arranged in the second contact space and configured to sense light at least if the second electrical connector is con nected to a first electrical connector, and a controller coupled to the light sensor and configured to determine a maximum output power based on the sensed light.

Further, it is provided:

A method for determining a maximum output power for providing electrical power from a second connector to a first connector, the method comprising generating light in a first outer enclosure of the first electrical connector that surrounds a first contact space and comprises an opening on a front side of the first electrical connector in longitudinal di rection of the first contact space, sensing the generated light in a second outer enclo sure of the second electrical contact that surrounds a second contact space and com prises an opening on a front side of the second electrical connector in longitudinal direc tion of the second contact space, and determining a maximum output power from the second electrical connector to the first electrical connector based on the sensed light.

The present invention is based on the finding, that measuring physical properties of the wires of a charging cable like e.g., the resistance of the wires, is a complex task, and that the physical properties of the wires or the contacts used to contact the wires may change over time, temperature and the like.

The present invention acknowledges this finding and provides a simple solution for de termining the current carrying capacity of a first electrical connector and a cable at tached to said connector.

To this end, the present invention provides the first electrical connector and the second electrical connector. In this regard it is noted, that the first electrical connector is the connector that may be coupled to a charging cable, while the second electrical con nector may be coupled to the charging station. Generally, the first electrical connector may be coupled to the element for which the current carrying capacity is to be deter mined, and the second electrical connector may be coupled to the element that com prises the electrical power source.

The first electrical connector comprises a first outer enclosure that encloses a first con tact space and accommodates a number of first electrical contacts and a light genera tion device. The first outer enclosure comprises an opening on a front side in longitudi nal direction of the first contact space. The longitudinal direction is defined by the direc tion of movement of the electrical connector when the electrical connector is coupled to or mated to a respective counterpart, i.e. the second electrical connector. It is under stood, that the term direction of movement in this case refers to a relative direction. This means that the second electrical connector may be moved instead of the first electrical connector. It is understood, that other electrical contacts may also be present either in the outer enclosure or outside of the outer enclosure.

The second electrical connector comprises a similar mechanical arrangement with a second outer enclosure that encloses a second contact space and accommodates a number of second electrical contacts. The second outer enclosure also comprises an opening on a front side in longitudinal direction of the second contact space. The longi tudinal direction is defined by the direction of movement of the second electrical con nector when the second electrical connector is coupled to or mated to a respective counterpart, i.e. the first electrical connector. It is understood, that the term direction of movement in this case refers to a relative direction. This means that the first electrical connector may be moved instead of the second electrical connector. It is understood, that other electrical contacts may also be present either in the outer enclosure or out side of the outer enclosure. Instead of a light generation device, the second electrical connector comprises a light sensor arranged in the second contact space.

It is understood, that the first electrical connector and the second electrical connector are counterparts and that, respectively, the first outer enclosure and the second outer enclosure are formed such that the two connectors may be connected to each other.

The first and the second connector may for example be connectors according to a re spective standard. Exemplary connectors include, but are not limited to, J1772 connect ors, Mennekes connectors, GB/T connectors, CCS1 connectors, CHAdeMO connect ors, CCS2 connectors, and vendor-specific connectors.

The current carrying capacity may be determined after the first electrical connector and the second electrical connector are coupled to each other and prior to initiating charging of an electrical vehicle.

If the current carrying capacity of the first electrical connector or the cable coupled to the first electrical contact is to be determined, the light generation device may emit light of a predefined type i.e. , light that has predefined characteristics.

The light generation device may for example comprise a LED for emitting light. It is un derstood, that for a specific current carrying capacity a respective LED that emits re spective light may be installed in the first electrical connector. If the characteristics of the emitted light are determined simply by choosing a respective LED, the same type of LED may be used for all first electrical connectors and respective charging cables that comprise the same current carrying capacity. Further, no complex active controller is re quired for such a light source. It is understood, however, that the light generation device may comprise further electrical components required to drive such a LED like e.g., re sistors, filters, voltage regulators and the like.

In the second electrical connector, the light sensor may sense the light, and a controller coupled to the light sensor may determine the maximum output power for the second electrical connector based on the sensed light.

The light sensor may for example comprise one or more photo diodes that sense the light that is emitted by the light generation device and provide a respective output signal to the controller. The controller determines the maximum output power for the second electrical connector, which reflects the current carrying capacity of the first electrical connector, based on the characteristics of the light sensed by the light sensor. After de termining the maximum output power, the controller may provide this information to a power source that provides the second electrical connector with electrical power. The power source may then limit the maximum output power to the respective value. Espe cially when charging an electrical vehicle, other factors that may be communicated e.g., between the charging station and the vehicle, may also influence the output power of the charging station and result in an even lower output power during charging. The max imum output power will however be limited to the determined value to prevent any dam age to the first electrical connector and the charging cable.

With the present invention it is possible, to easily determine the current carrying capac ity for a respective charging cable that is used to charge an electrical vehicle. The cir cuitry required in the first electrical connector may be a passive circuitry without active control circuits and may therefore easily be implemented in the first electrical connector. At the same time, the receiving circuit in the second electrical connector also is of very low complexity.

Since the emitted light is transmitted via and evaluated in the first and second contact spaces, when the first electrical connector and the second electrical connector are cou pled to each other, the detection is very robust against interferences.

Further embodiments of the present disclosure are subject of the further dependent claims and of the following description, referring to the drawings.

In an embodiment, the light generation device may be coupled to the first electrical con tacts and may be configured to receive electrical supply energy via the first electrical contacts.

The light generation device may be coupled e.g., to two of the first electrical contacts and may be provided with electrical supply energy to emit the light via these first electri cal contacts. It is understood, that the first electrical connector comprises a plurality of first electrical contacts, wherein different contacts may be provided for different volt ages, currents and power levels. For example, the first electrical connector may com- prise a positive high-power electrical contact and a negative high-power electrical con tact. In addition, the first electrical connector may comprise electrical low-power and/or data contacts. The light generation device may in such an embodiment be coupled to the electrical low-power and/or data contacts.

The second electrical connector or the power supply coupled to the second electrical connector may provide such electrical low-power and/or data contacts with electrical power prior to providing electrical power to high-power electrical contacts. Therefore, the determination of the current carrying capacity and the maximum output power may be determined prior to providing high amounts of electrical power to the first electrical connector.

As alternative the light generation device may be supplied with electrical supply energy via the other end of the cable or an electrical device to which the first electrical con nector is coupled to, for example an electrical vehicle.

In another embodiment, the light generation device may be configured to emit light with a predetermined light intensity. The light sensor may be configured to sense the light in tensity of the light, and the controller may be configured to determine the maximum out put power based on the sensed light intensity.

The light intensity may be defined according to a current carrying capacity of the first electrical connector or the cable or electrical device, like an electric vehicle, connected to the first electrical connector.

The light intensity may simply be determined by providing the light generation device with a respective input power. In case of the light generation device comprising a LED, the light intensity may be fixed to the predetermined light intensity by providing a re spective driving current to the LED. To this end, either a simple series resistor with the respective resistance may be used or a dedicated current source with the respective output current may be used.

The light sensor may for example be a photo diode that may provide an output signal that represents the received light intensity.

In another embodiment, the light generation device may be configured to emit light with a predetermined light color. The light sensor may be configured to sense a light color of the sensed light, and the controller may be configured to determine the maximum output power based on the sensed light color.

As with the light intensity, the light color may be defined according to the current carry ing capacity of the first electrical connector or the cable or electrical device connected to the first electrical connector. The light color may simply be defined by providing a light source with the respective color, for example a red LED, a green LED, a blue LED, or the like. A respective current carrying capacity may be assigned to each color.

The light sensor may comprise respective sensor elements, like for example photo di odes with respective color filters that allow determining if light of a respective color is present or not.

Detecting the color of the light may make the detection more robust, since the intensity of emitted light may be modified e.g., by dirt on the light emitter or the light sensors.

In another embodiment, the light generation device may be configured to emit light with a predetermined frequency and/or a predetermined duty cycle. The light sensor may be configured to sense a frequency of the sensed light, and the controller may be config ured to determine the maximum output power based on the sensed frequency.

The term frequency in this regard does not refer to the frequency of the light waves, in stead frequency in this regard refers to a modulation frequency used for turning on and off the light. It is understood, that the modulation may also comprise a predetermined duty cycle, like in a PWM signal. To generate light of a predetermined frequency and/or duty cycle in the light generation device, a simple oscillator circuit e.g., based on a 555 timer component or a programable component, like a processor or controller, may be used.

As with the light intensity and the light color the frequency may be defined according to a current carrying capacity of the first electrical connector or the cable or electrical de vice connected to the first electrical connector.

In the second electrical connector the light sensor may determine the frequency of the sensed light e.g., with a frequency to voltage converter, or with a timer/counter-based component. It is understood, that the frequency determination part may also be provided in the con troller. In such an embodiment, the light sensor provides a raw signal to the controller and the controller evaluates the signal.

Detecting the frequency of the light also makes the detection more robust, since the in tensity of emitted light may be modified e.g., by dirt on the light emitter or the light sen sors.

In a further embodiment, the first electrical connector may comprise a switch coupled to an electrical supply input of the light generation device and configured to close an elec trical contact for the electrical supply input if the first electrical connector is coupled to the second electrical connector.

The switch may serve for determining when the first electrical connector is coupled to the second electrical connector. Especially, in embodiments, in which the first electrical connector is coupled to a cable that may already be powered e.g. because it is con nected on the other end to an electrical vehicle, light generation may be delayed with the switch until the first electrical connector is coupled to the second electrical con nector.

In yet another embodiment, the second electrical connector may comprise a power sup ply coupled to the controller and to the second electrical contacts. The power supply may be configured to supply electrical power to the second electrical contacts according to the determined maximum output power.

As explained above, determining the maximum output power serves for protecting the first electrical connector or the attached cable from overload. Therefore, after determin ing this information in the second electrical connector, the power source supplying the second electrical connector with electrical power may be configured accordingly.

It is understood, that the second electrical connector may be provided in an electrical device, like e.g. a charging station for electrical vehicles. In such an embodiment, the mechanical parts, like the second outer enclosure may be provided integrally with an enclosure of the respective electrical device. Further, elements described herein as be ing part of the second electrical connector, in such an embodiment may be provided in the electrical device and may be coupled to the second electrical connector. BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present disclosure and advantages thereof, reference is now made to the following description taken in conjunction with the accom panying drawings. The disclosure is explained in more detail below using exemplary embodiments which are specified in the schematic figures of the drawings, in which:

Figure 1 shows a block diagram of an embodiment of a first electrical connector accord ing to the present disclosure;

Figure 2 shows a perspective view of another embodiment of a first electrical connector according to the present disclosure;

Figure 3 shows a sectional view of the embodiment of a first electrical connector of Fig ure 2;

Figure 4 shows a block diagram of an embodiment of a second electrical connector ac cording to the present disclosure;

Figure 5 shows a sectional view of an embodiment of a second electrical connector ac cording to the present disclosure;

Figure 6 shows a block diagram of an embodiment of a charging station with an embod iment of a second electrical connector according to the present disclosure; and

Figure 7 shows a flow diagram of an embodiment of a method according to the present disclosure.

In the figures like reference signs denote like elements unless stated otherwise.

DETAILED DESCRIPTION OF THE DRAWINGS

Figure 1 shows a block diagram of a first electrical connector 100. The first electrical connector 100 comprises a first outer enclosure 101 that surrounds a first contact space 102 with an opening in longitudinal direction 112 of the first electrical connector 100.

The first outer enclosure 101 surrounds the first contact space 102 such that and a number of first electrical contacts 103, 104 can be arranged in the first contact space 102. In the first electrical connector 100 two first electrical contacts 103, 104 are shown. However, more possible electrical contacts are hinted at by three dots. Generally, any number of contacts required by the respective application may be provided in the first electrical connector 100.

Further, a light generation device 107 is arranged in the first contact space 102 such that light emitted by the light generation device 107 is emitted at least in part in the di rection of the opening of the first contact space 102. The light generation device 107 is exemplarily coupled to the wires of the first electrical contacts 103, 104 and receives electrical supply energy via the first electrical contacts 103, 104.

The light generation device 107 may emit light 108 with a predetermined light intensity and/or light color. In addition, or as alternative, the light generation device 107 may emit light 108 with a predetermined frequency and/or a predetermined duty cycle.

Although not explicitly shown, the first electrical connector 100 may comprise a switch coupled to an electrical supply input of the light generation device 107 that closes an electrical contact for the electrical supply input if the first electrical connector 100 is cou pled to a respective second electrical connector.

Figure 2 shows a perspective view of another first electrical connector 200. The first electrical connector 200 is based on the first electrical connector 100. Therefore, the first electrical connector 200 also comprises a first outer enclosure 201 that surrounds a first contact space 202 that comprises an opening in longitudinal direction 212. The first outer enclosure 201 accommodates three first electrical contacts 203, 204, 205. On the side of the first outer enclosure 201 opposite to the opening a cable 211 is provided, that is internally coupled to the first electrical contacts 203, 204, 205.

Again, it is understood, that the number of three first electrical contacts 203, 204, 205 is just exemplarily chosen and that any other number of first electrical contacts is possible.

Figure 3 shows a sectional view of the first electrical connector 200. In the first contact space 202 the light generation device 207 is provided at an inner wall at the back of the first contact space 202 such that the emitted light is oriented to the opening of the first contact space 202.

Figure 4 shows a block diagram of a second electrical connector 350 that may be coupled to a respective first electrical connector. The second electrical connector 350 comprises a second outer enclosure 351 that surrounds a second contact space 352. In the second contact space 352 two second electrical contacts 353, 354 are provided. Further second electrical contacts are hinted at by three dots. It is understood, that any number of second electrical contacts 353, 354 is possible.

The second electrical connector 350 further comprises a light sensor 357 that is ar ranged in the second contact space 352. Further, a controller 358 is provided that is coupled to the light sensor 357.

For determining a maximum output power 359 for the second electrical connector 350, the light sensor 357 senses light 308, that is emitted from the light generation device in a respective first electrical connector, if the second electrical connector 350 is con nected to the first electrical connector. The controller 358 then determines the maxi mum output power 359 based on the sensed light 308, and may provide this information for example to a power source of a charging station for electrical vehicles.

The light sensor 357 may sense the light intensity of the light 308 and the controller 358 may determine the maximum output power 359 based on the sensed light intensity. In addition, or as alternative, the light sensor 357 may sense a light color of the sensed light 308 and the controller 358 may determine the maximum output power 359 based on the sensed light color. Further, in addition, or as alternative, the light sensor 357 may sense a frequency of the sensed light 308 and the controller 358 may determine the maximum output power 359 based on the sensed frequency.

Although not explicitly shown, the second electrical connector 350 may comprise a power supply coupled to the controller 358 and to the second electrical contacts 353, 354, 453. The power supply may supply electrical power to the second electrical con tacts 353, 354 according to the determined maximum output power 359 determined by the controller 358.

Figure 5 shows a sectional view of a second electrical connector 450. The second elec trical connector 450 is based on the second electrical connector 350. Therefore, the second electrical connector 450 comprises a second outer enclosure 451 that sur rounds a second contact space 452 with an opening in longitudinal direction 412. Three second electrical contacts 453, 454, of which only two are visible, are provided in the second contact space 452. A cable 411 is coupled to the end opposite of the opening to the second outer enclosure 451. Internally the wires of the cable 411 are coupled to the second electrical contacts 453, 454.

A light sensor 457 is provided inside of the second outer enclosure 451 on a back wall. The light sensor 457 receives light emitted by a light generation device of a first electri cal connector, when the second electrical connector 450 is coupled to a respective first electrical connector and provides a respective signal to a controller (not shown in Figure 5).

Figure 6 shows a block diagram of a charging station 570. The charging station 570 comprises a power source 571 that is supplied with electrical power via a mains power supply 572. The power source 571 is coupled to a second electrical connector 550 that is provided on the charging station 570 for charging electrical vehicles via a respective charging cable that comprises a respective first electrical connector, for example a con nector as shown in Figures 1 to 3.

The second electrical connector 550 comprises two electrical connectors 553. 554 and a light sensor 557. The light sensor 557 senses light emitted by a light generation de vice in the first electrical connector of the charging cable and provides a respective sig nal to controller 558. In the charging station 570 the controller 558 is exemplarily pro vided outside of the second electrical connector 550.

The controller 558 evaluates the signal provided by the light sensor 557 and controls the power source 571 accordingly, to supply electrical power with a power level i.e., with a current and/or voltage, that is below the capacity of the charging cable.

For sake of clarity in the following description of the method-based Fig. 7 the reference signs used above in the description of apparatus based Figs. 1 - 6 will be maintained.

Figure 7 shows a flow diagram of a method for determining a maximum output power 359 for providing electrical power from a second electrical connector 350, 450, 550 to a first electrical connector 100, 200.

The method comprises generating S1 light 108, 208, 308, 408 in a first outer enclosure 101 , 201 of the first electrical connector 100, 200 that surrounds a first contact space 102, 202 and comprises an opening on a front side of the first electrical connector 100, 200 in longitudinal direction 112, 212 of the first contact space 102, 202, sensing S2 the generated light 108, 208, 308, 408 in a second outer enclosure 351 , 451 of the second electrical contact 353, 354, 453, 454, 553, 554 that surrounds a second contact space 352, 452 and comprises an opening on a front side of the second electrical connector 350, 450, 550 in longitudinal direction 412 of the second contact space 352, 452, and determining S3 a maximum output power 359 from the second electrical connector 350, 450, 550 to the first electrical connector 100, 200 based on the sensed light 108, 208, 308, 408.

The light 108, 208, 308, 408 may be generated based on electrical supply energy that is received via first electrical contacts 103, 104, 203, 204, 205 arranged in the first contact space 102, 202 from second electrical contacts 353, 354, 453, 454, 553, 554 arranged in the second contact space 352, 452.

Further, there are different possibilities to characterize the current carrying capacity of the first electrical contact with the light 108, 208, 308, 408. The light 108, 208, 308, 408 may for example be emitted with a predetermined light intensity, and the light intensity may be sensed and the maximum output power 359 may be determined based on the sensed light intensity.

In addition, or as alternative, the light 108, 208, 308, 408 may be emitted with a prede termined light color, and the light color may be sensed and the maximum output power 359 may be determined based on the sensed light color.

Further, the light 108, 208, 308, 408 may be emitted with a predetermined frequency, and the frequency may be sensed and the maximum output power 359 may be deter mined based on the sensed frequency.

The method may also comprise activating an electrical supply for generating the light 108, 208, 308, 408 only if the first electrical connector 100, 200 coupled to the second electrical connector 350, 450, 550.

Although specific embodiments have been illustrated and described herein, it will be ap preciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations exist. It should be appreciated that the exemplary embodiment or ex emplary embodiments are only examples, and are not intended to limit the scope, ap plicability, or configuration in any way. Rather, the foregoing summary and detailed de- scription will provide those skilled in the art with a convenient road map for implement ing at least one exemplary embodiment, it being understood that various changes may be made in the function and arrangement of elements described in an exemplary em bodiment without departing from the scope as set forth in the appended claims and their legal equivalents. Generally, this application is intended to cover any adaptations or var iations of the specific embodiments discussed herein.

LIST OF REFERENCE SIGNS

100, 200 first electrical connector 101, 201 first outer enclosure 102, 202 first contact space 103, 104, 203, 204, 205 first electrical contact

107, 207 light generation device

108, 208, 308, 408 light

109, 110 wire 211 , 411 cable 112, 212, 412 longitudinal direction

350, 450, 550 second electrical connector 351 , 451 second outer enclosure 352, 452 second contact space 353, 354, 453, 454, 553, 554 second electrical contact

357, 457, 557 light sensor

358, 458, 558 controller 359 maximum output power 570 charging station

571 power source

572 mains power supply