Electric propulsion vehicle charging cable and power adapter attached to electric propulsion vehicle charging cable

To provide the electric propulsion vehicle charging cable compatible with power sources of different standards, and the power adapter attached to an electric propulsion vehicle charging cable, the power plug of the electric propulsion vehicle charging cable includes has an electrode structure including three high-voltage electrodes and a high-voltage ground pin, the electric propulsion vehicle charging cable used for charging a battery of the electric propulsion vehicle by using two of the three high-voltage electrodes, and the power adapter has electrode receptacles to which the three high-voltage electrodes and the high-voltage ground pin are connected and connection terminals having an electrode structure corresponding to a power source of a different standard from the electrode structure of the power plug.

TECHNICAL FIELD

The present disclosure relates to an electric propulsion vehicle charging cable used for charging a battery of an electric propulsion vehicle such as an electric vehicle or a hybrid vehicle, for example, and a power adapter attached to an electric propulsion vehicle charging cable.

BACKGROUND ART

Electric propulsion vehicles are recently continuously developed as environmentally-friendly automobiles at a fast pace. Charging infrastructures for electric propulsion vehicles include residential charging facilities using a residential power source at an end of a power network, and public charging facilities disposed in an urban area and basically available to unspecified number of people. Regarding the electric propulsion vehicles, important issues for popularization of the electric propulsion vehicles is to make a charging operation easy and to reduce a charging time.

When a user utilizes a charging facility to charge a battery of an electric propulsion vehicle, an electric propulsion vehicle charging cable (hereinafter abbreviated as a charging cable) is used for connecting a power source in the charging facility and a connector on the electric propulsion vehicle side. A configuration using such a charging cable has been proposed for achieving a reduction in charging time (see, e.g., Patent Literature 1).

CITATION LIST

Patent Literatures

SUMMARY OF INVENTION

Technical Problem

The charging facilities use various power sources having different power-supply voltages and power plugs (electrode structures) such as a residential power source of 100 V/200 V single-phase AC and an industrial power source having of 200 V three-phase AC. However, it is difficult to prepare multiple charging cables corresponding to the various power sources of the charging facilities in an electric propulsion vehicle due to a limited space for storing the charging cable. For achieving a reduction in the charging time (rapid charging), it is desirable to use a power plug with large rated values, for example, a power plug with a rated voltage of 250 V and a rated current of 50 A, as a charging cable. However, since a 100 V residential power source may be used for charging a battery of an electric propulsion vehicle, the vehicle must include, for example, a charging cable provided with a power plug having a rated voltage of 125 V and a rated current of 15 A, in addition to a charging cable provided with a power plug having a rated voltage of 250 V and a rated current of 50 A.

Furthermore, in other countries, for example, in the United States, 115 V/230 V single-phase AC and 230 V three-phase AC power sources are used, and respective corresponding power plugs are different. On continents such as Europe, where multiple countries with different power-supply voltages are connected by land, the electric propulsion vehicle moves across regions and borders with different power-supply voltages, and therefore, the vehicle must be equipped in advance with charging cables corresponding to various power source situations in the regions or countries.

However, as described above, the electric propulsion vehicle cannot be equipped with many charging cables due to a limited space for storing the charging cables, which is a major obstacle for popularizing the electric propulsion vehicles.

The present disclosure was conceived in view of the problems as described above and an object thereof is to provide an electric propulsion vehicle charging cable compatible with power sources of different standards, and a power adapter attached to an electric propulsion vehicle charging cable.

Solution to Problem

To achieve the object, the present disclosure provides

an electric propulsion vehicle charging cable having one end provided with a power plug connected to a power source of a charging facility and the other end provided with a charging coupler detachably connected via a control unit to an electric propulsion vehicle, wherein

the power plug has an electrode structure including three high-voltage electrodes and a high-voltage ground pin, the electric propulsion vehicle charging cable used for charging a battery of the electric propulsion vehicle by using two of the three high-voltage electrodes, and wherein

the electric propulsion vehicle charging cable has a power adapter including electrode receptacles to which the three high-voltage electrodes and the high-voltage ground pin are connected and connection terminals having an electrode structure corresponding to a power source of a different standard from the electrode structure of the power plug.

The present disclosure also provides

a power adapter attached to an electric propulsion vehicle charging cable having one end provided with a power plug connected to a power source of a charging facility and the other end provided with a charging coupler detachably connected via a control unit to an electric propulsion vehicle, wherein the power plug has an electrode structure including three high-voltage electrodes and a high-voltage ground pin, the electric propulsion vehicle charging cable used for charging a battery of the electric propulsion vehicle by using two of the three high-voltage electrodes, and wherein the power adapter includes electrode receptacles to which the three high-voltage electrodes and the high-voltage ground pin are connected and connection terminals having an electrode structure corresponding to a power source of a different standard from the electrode structure of the power plug.

Advantageous Effects of Invention

The present disclosure enables provision of the electric propulsion vehicle charging cable compatible with power sources of different standards, and the power adapter attached to an electric propulsion vehicle charging cable.

DESCRIPTION OF EMBODIMENTS

In each of aspects of the present disclosure described below, main elements are denoted by reference numerals described in a first embodiment described below, and these reference numerals are merely intended to facilitate understanding, rather than limiting the present disclosure to the configuration described in the embodiments.

An electric propulsion vehicle charging cable (1) according to a first aspect of the present disclosure has one end provided with a power plug (12) connected to a power source of a charging facility and the other end provided with a charging coupler (11) detachably connected via a control unit (9) to an electric propulsion vehicle, wherein

the power plug has an electrode structure including three high-voltage electrodes (14a,14b,14c) and a high-voltage ground pin (15), the electric propulsion vehicle charging cable used for charging a battery of the electric propulsion vehicle by using two (14a,14b) of the three high-voltage electrodes, and wherein

the electric propulsion vehicle charging cable has a power adapter (13) including electrode receptacles (20,21,22,23) to which the three high-voltage electrodes and the high-voltage ground pin are connected and connection terminals (18a,18b,19) having an electrode structure corresponding to a power source of a different standard from the electrode structure of the power plug.

In the electric propulsion vehicle charging cable according to a second aspect of the present disclosure, the connection terminals of the power adapter in the first aspect have an electrode structure including two low-voltage electrodes (18a,18b) and a low-voltage ground pin (19) of a different standard from the electrode structure of the power plug, wherein

in the power adapter, the electrode receptacle (22or23) to be connected to one high-voltage electrode (14c) not used as a charging electrode among the three high-voltage electrodes of the power plug and the electrode receptacle (23or22) to be connected to the high-voltage ground pin (15) may be electrically connected to each other, and wherein

the two low-voltage electrodes (18a,18b) may be respectively electrically connected to two electrode receptacles (20,21) respectively connected to the two high-voltage electrodes (14a,14b) used as charging electrodes among the three high-voltage electrodes of the power plug.

The electric propulsion vehicle charging cable according to a third aspect of the present disclosure, in the electric propulsion vehicle charging cable of the second aspect, wherein

the power adapter includes four electrode holes (13a,13b) into which the three high-voltage electrodes and the high-voltage ground pin of the power plug may be inserted and led to respective electrode receptacles (20,21,22,23), wherein

the four electrode holes may be symmetrically arranged on a contact surface (13e) for the power plug, and wherein

among the four electrode holes, the electrode hole (13b) leading to the electrode receptacle (22or23) to be connected to the one high-voltage electrode (14c) not used as the charging electrode may have substantially the same shape as the electrode hole (13b) leading to the electrode receptacle (23or22) to be connected to the high-voltage ground pin (15).

In the electric propulsion vehicle charging cable according to a fourth aspect of the present disclosure, the power adapter of the third aspect may be configured to be attached to the power plug at positions rotated by 180 degrees from each other with respect to a center of arrangement of the four electrode holes on the contact surface for the power plug.

In the electric propulsion vehicle charging cable according to a fifth aspect of the present disclosure, in the power adapter of the fourth aspect, the electrode hole (13b) leading to the electrode receptacle (22or23) to be connected to the one high-voltage electrode (14c) not used as the charging electrode and the electrode hole (13b) leading to the electrode receptacle (23or22) to be connected to the high-voltage ground pin (15) may be arranged on an arrangement center line (P) included on the contact surface, and wherein

the two electrode holes (13a) leading to the electrode receptacles (20,21) respectively connected to the two high-voltage electrodes (14a,14b) used as the charging electrodes may be symmetrically arranged on both sides of the arrangement center line.

In the electric propulsion vehicle charging cable according to a sixth aspect of the present disclosure, in any of the first aspect to fifth aspect, the power adapter may include locking means (17) engaging with the attached power plug.

In a power adapter attached to an electric propulsion vehicle charging cable (1) according to a seventh aspect of the present disclosure having one end provided with a power plug (12) connected to a power source of a charging facility and the other end provided with a charging coupler (11) detachably connected via a control unit (9) to an electric propulsion vehicle,

the power plug may have electrode structure including three high-voltage electrodes (14a,14b,14c) and a high-voltage ground pin (15), the electric propulsion vehicle charging cable used for charging a battery of the electric propulsion vehicle by using two (14a,14b) of the three high-voltage electrodes, wherein

the power adapter may include electrode receptacles (20,21,22,23) to which the three high-voltage electrodes and the high-voltage ground pin may be connected and connection terminals (18a,18b,19) having an electrode structure corresponding to a power source of a different standard from the electrode structure of the power plug.

In a power adapter attached to an electric propulsion vehicle charging cable according to an eighth aspect of the present disclosure, in the seventh aspect, the connection terminals of the power adapter may have an electrode structure including two low-voltage electrodes (18a,18b) and a low-voltage ground pin (19) of a different standard from the electrode structure of the power plug, wherein

the electrode receptacle (22or23) to be connected to one high-voltage electrode (14c) not used as a charging electrode among the three high-voltage electrodes of the power plug and the electrode receptacle (23or22) to be connected to the high-voltage ground pin (15) may be electrically connected to each other, and wherein

the two low-voltage electrodes (18a,18b) may be respectively electrically connected to two electrode receptacles (20,21) respectively connected to the two high-voltage electrodes (14a.14b) used as charging electrodes among the three high-voltage electrodes of the power plug.

In a power adapter attached to an electric propulsion vehicle charging cable according to a ninth aspect of the present disclosure, in the eighth aspect, the power adapter may include four electrode holes (13a,13b) into which the three high-voltage electrodes and the high-voltage ground pin of the power plug may be inserted and led to respective electrode receptacles (20,21,22,23), wherein

the four electrode holes may be symmetrically arranged on a contact surface (13e) for the power plug, and wherein

among the four electrode holes, the electrode hole (13b) leading to the electrode receptacle (22or23) to be connected to the one high-voltage electrode (14c) not used as the charging electrode may have substantially the same shape as the electrode hole (13b) leading to the electrode receptacle t (23or22) o be connected to the high-voltage ground pin (15).

In a power adapter attached to an electric propulsion vehicle charging cable according to a tenth aspect of the present disclosure, the power adapter of the ninth aspect may be configured to be attached to the power plug at positions rotated by 180 degrees from each other with respect to a center of arrangement of the four electrode holes on the contact surface for the power plug.

In a power adapter attached to an electric propulsion vehicle charging cable according to an eleventh aspect of the present disclosure, in the tenth aspect, the electrode hole (13b) leading to the electrode receptacle (22or23) to be connected to the one high-voltage electrode (14c) not used as the charging electrode and the electrode hole (13b) leading to the electrode receptacle (23or22) to be connected to the high-voltage ground pin (15) may be arranged on an arrangement center line (P) included on the contact surface, and wherein

the two electrode holes (13a) leading to the electrode receptacles (20,21) respectively connected to the two high-voltage electrodes (14a,14b) used as the charging electrodes may be symmetrically arranged on both sides of the arrangement center line.

In a power adapter attached to an electric propulsion vehicle charging cable according to a twelfth aspect of the present disclosure, in any of the seventh aspect to eleventh aspect, the power adapter may include locking means (17) engaging with the attached power plug.

Embodiments according to the present disclosure will now be described with reference to the accompanying drawings. In the drawings, the same elements are denoted by the same reference numerals and may not be described. The drawings schematically show respective constituent elements for ease of understanding.

The embodiments described below show a specific example of the present disclosure. Numerical values, shapes, configurations, etc. described in the following embodiments are merely examples and do not limit the present disclosure. Among the constituent elements in the following embodiments, constituent elements not described in the independent claim describing the highest concept are described as optional constituent elements. the same applies to configurations of modifications in the embodiments, and the configurations described in the modifications may be combined with each other.

First Embodiment

FIG. 1schematically shows a state of an electric propulsion vehicle charging cable1of the first embodiment according to the present disclosure (hereinafter, simply referred to as a “charging cable1”) used for charging a battery5of an electric propulsion vehicle2from a residential power source (100 V/200 V) used in general homes as a charging facility.

The charging cable1has a configuration enabling charging of the electric propulsion vehicle2from a general residential power source (100 V/200 V) disposed on a residential exterior wall of a general home as well as from a power source facility (three-phase 200 V) of a different standard.

As shown inFIG. 1, the battery5of the electric propulsion vehicle2is charged by connecting the electric propulsion vehicle2via the charging cable1to a high-voltage residential power source A (200 V). The electric propulsion vehicle2has configuration in which the battery5of the electric propulsion vehicle2can be charged also from a low-voltage residential power source B (100 V) of a standard different from the high-voltage residential power source A (200 V) by using the charging cable1to which a power adapter13described later is attached.

While rapid charging can obviously be performed with a high voltage and a large current, the charging cable1is configured such that charging can appropriately be performed according to the standards of the respective residential power supplies A, B.

The electric propulsion vehicle2includes a motor3for running, an inverter4, a battery5, and a charging control device6, which are electrically connected to each other. The electric propulsion vehicle2is connected to the charging cable1via a connector7connected to the charging control device6. The charging cable1is connected to the high-voltage 200 V residential power source A, for example, and is used for charging the battery5mounted on the electric propulsion vehicle2. The charging cable1has a configuration compatible with a power source of a different standard such as the low-voltage residential power source B (100 V) commonly used in general homes so that the battery5mounted on the electric propulsion vehicle2can optimally be charged according to the standard of the power source.

FIG. 2is an overall view showing the charging cable1according to the first embodiment. As shown inFIG. 2, the charging cable1includes a control unit9and is provided with a power-source-side cable8led out from the control unit9toward the power source and a vehicle-side cable10led out toward the electric propulsion vehicle. A charging coupler11detachably connected to the connector7of the electric propulsion vehicle2is disposed at a leading end portion of the vehicle-side cable10. On the other hand, a power plug12to be attached to a charging facility such as a residential power source (A, B) is disposed at a leading end portion of the power-source-side cable8.

The power plug12has electrode plates14(14a,14b,14c) and one ground pin (15) as a connection terminal so as to be connected to the 200 V residential power source A (SeeFIG. 4described later). The power plug12is configured such that the power adapter13(seeFIG. 7described later) having two electrode plates (18a,18b) and one ground pin (19) may be attached to the power plug12, so that the charging cable1in the first embodiment is used also with the low-voltage residential power source B (100 V) commonly used in general homes. The charging cable1includes the power adapter13in the description of the present disclosure; however, the power adapter13is independently distributed in the market as a power adapter of the electric propulsion vehicle charging cable1.

In the power plug12, a temperature sensor (e.g., a resistance temperature detector) is embedded as temperature detecting means near the electrode plates (14a,14b). Temperature information of the power plug12detected by the temperature sensor (16: seeFIG. 5) is transmitted via the power-source-side cable8to the control unit9. The control unit9has a configuration capable of monitoring the temperature of the power plug12.

The power plug12and the power adapter13of the charging cable1according to the first embodiment will hereinafter be described.

FIG. 3is a side view showing the power plug12disposed at an end portion of the power-source-side cable8in the first embodiment. InFIG. 3, the three electrode plates14and the ground pin15are projected on the left side of the power plug12.FIG. 4is a front view of the power plug12, showing the connection terminal side on which the three electrode plates14(14a,14b,14c) and the ground pin15are projected.FIG. 5is a vertical cross-sectional view of a substantially central portion of the power plug12shown inFIG. 3.

As shown inFIG. 3, the power plug12of the charging cable1of the first embodiment has an electrode structure having the three high-voltage electrodes (14:14a,14b,14c) and the ground pin15. The two high-voltage electrodes (14a,14b) of the three high-voltage electrodes are used as charging electrodes. The power plug12includes a main body part12aprovided with the three electrode plates14(14a,14b,14c) serving as high-voltage electrodes and the ground pin15, and a lead-out part12bfor leading out the power-source-side cable8from the main body part12a. On the main body part12aof the power plug12, the electrode plates14and the ground pin15are disposed to project in a direction orthogonal to a contact surface12ecoming into contact with a power outlet serving as a power plug receptacle. The lead-out part12bguides the power-source-side cable8from the main body part12asuch that the cable is led out parallel to the contact surface12e, i.e., vertically downward. Therefore, as shown inFIG. 3, the power plug12has the electrode plates14and the ground pin15projected from the contact surface12ein a horizontal direction. The power-source-side cable8is formed such that the cable is led out vertically downward. Thus, the power plug12has a configuration in which the projection direction of the electrode plates14and the ground pin15is substantially orthogonal to the lead-out direction of the power-source-side cable8.

As shown inFIGS. 3 and 4, connection terminals of the power plug12are the three electrode plates14(14a,14b,14c) and the ground pin15for grounding projected from the contact surface12e. The first electrode plate14aand the second electrode plate14bof the three electrode plates14(14a,14b,14c) of the power plug12are the two high-voltage electrodes used as 200 V charging electrodes. When the power plug12is connected to the three-phase three-wire 200 V residential power source A in use, the third electrode plate of the power plug12, i.e., the third electrode plate14c, is not used. Therefore, in the power plug12, the third electrode plate14cis not electrically connected to anywhere and is kept in a so-called electrically floating state.

As shown inFIG. 4, in the connection terminals of the power plug12, the first electrode plate14aand the second electrode plate14bare flat plate-shaped lead-out portions connected to the power source and arranged such that respective flat surfaces face each other. The third electrode plate14chas the same plate lead-out shape as the first electrode plate14aand the second electrode plate14b, has a projecting position on a center line included in the contact surface12ebetween the first electrode plate14aand the second electrode plate14b, and is located at a position shifted from a facing position of the first electrode plate14aand the second electrode plate14b(a position offset downward inFIG. 4).

As described above, in the charging cable1according to the first embodiment, the first electrode plate14a, the second electrode plate14b, and the third electrode plate14cof the power plug12symmetrically arranged on the contact surface12eof the power plug12for the power outlet that is the residential power source A (200 V). The third electrode plate14cis disposed on the center line that is an intermediate position between the first electrode plate14aand the second electrode plate14bfacing each other.

The ground pin15is disposed on the center line and is located at a position shifted from a facing position of the first electrode plate14aand the second electrode plate14b(a position offset upward inFIG. 4). Therefore, the four connection terminals of the power plug12, i.e., the first electrode plate14a, the second electrode plate14b, the third electrode plate14c, and the ground pin15are arranged symmetrically with respect to the center line between the first electrode plate14aand the second electrode plate14b. For the electrode arrangement of the connection terminals of the power plug12in the first embodiment, for example, NEMA 14-50 (rated voltage: 240 V, rated current: 50 A) in the NEMA (National Electrical Manufacturers Association) standards is used. The charging cable1according to the first embodiment has a configuration on the assumption of US power source standards.

As described above, in the power plug12according to the first embodiment, the lead-out part12bis disposed on the lower side of the main body part12aso that the power-source-side cable8is lead out vertically downward from the main body part12a. The ground pin15and the third electrode plate14care symmetrically arranged at upper and lower positions relative to the facing position of the first electrode plate14aand the second electrode plate14barranged to face each other. Specifically, the ground pin15is disposed on the upper side relative to the facing position of the first electrode plate14aand the second electrode plate14b, and the third electrode plate14cis disposed on the lower side relative to the facing position of the first electrode plate14aand the second electrode plate14b.

As shown inFIGS. 3 and 4, in the configuration of the first embodiment, position regulating grooves12d,12dare formed on both side surfaces of the main body part12aof the power plug12(seeFIGS. 3 and 4). The position regulating grooves12d,12dare disposed to extend in a direction orthogonal to the contact surface12eat opposite positions on both side surfaces of the main body part12a.

As shown inFIG. 5, the third electrode plate14cdisposed to project from the main body part12ain a substantially horizontal direction has an electrode portion embedded in the main body part12aand fixed to the main body part12aand is not electrically connected to anywhere. The temperature sensor16(resistance temperature detector) is disposed near an electrode part in the main body part12afor each of the first electrode plate14aand the second electrode plate14b. An electric signal (temperature information) from the temperature sensor16disposed for each of the first electrode plate14aand the second electrode plate14bis transmitted through the power-source-side cable8to the control unit9. The control unit9has a configuration capable of monitoring the respective temperatures of the first electrode plate14aand the second electrode plate14b.

The control unit9includes an opening/closing circuit28(e.g., a relay) opening and closing a charging electric path between the power plug12and the charging coupler11, and a leakage detecting part29monitoring a current flowing through the charging electric path to detect electric leakage (seeFIG. 11described later). When an abnormal temperature is detected from the temperature information from the temperature sensors16, a control part25in the control unit9transmits a pilot signal to the charging control device6of the electric propulsion vehicle2to reduce a charging current. When the leakage detecting part29detects electric leakage, the control part25interrupts the charging electric path via the opening/closing circuit28to stop the power supply from the power source (A, B) of the charging facility to the electric propulsion vehicle2.

FIG. 6is a plan view of the power adapter13in the first embodiment 1 as viewed from above.FIG. 7is a front view (a), a side view (b), and a rear view (c) of the power adapter13in the first embodiment.

As shown inFIG. 6, the power adapter13has a male electrode structure projected for connection to a general residential power source (100 V) and a female electrode structure connected to the connection terminals of the power plug12described above. As described later, the female electrode structure of the power adapter13has a special electrode structure such that the power adapter13is easily and safely connected to the power plug12even in a state of being rotated by 180 degrees relative to the power plug12.

Additionally, the power adapter13is provided with locking means for preventing the power plug12from coming off. The locking means of the power adapter13are made up of locking claws17. When the power adapter13is properly connected to the power plug12, the locking claws17of the power adapter13engage with locking parts12c(seeFIG. 5) that are concave portions formed on the side surfaces of the power plug12.

As shown inFIG. 7, on one surface of the power adapter13(the surface on the power source side shown in (a) ofFIG. 7), two electrode plates18serving as low-voltage electrodes connected to a 100 V power source (18a,18b) and a ground pin19serving as a low-voltage ground pin are projected. The other surface of the power adapter13(the surface on the power plug side shown in (c) ofFIG. 7) is provided with two first/second electrode holes (13a,13a) into which the first electrode plate14aor the second electrode plate14bof the power plug12for 200 V is inserted, and two third/ground electrode holes (13b,13b) into which the third electrode plate14cor the ground pin15is inserted.

As shown in (c) ofFIG. 7, the two first/second electrode holes (13a,13a) and the two third/ground electrode holes (13b,13b) are symmetrically arranged on a contact surface13eof the power adapter13for the power plug12. Even when rotated 180 degrees on the contact surface13ewith respect to an arrangement center C that is a center point at the same distance from the four electrode holes (13a,13a,13b,13b), the four electrode holes (13a,13a,13b,13b) are arranged in the same way. As shown in (c) ofFIG. 7, the two third/ground electrode holes (13b,13b) are formed at upper and lower positions relative to the arrangement center C on an arrangement center line P including the arrangement center C on the contact surface13e. On the other hand, the two first/second electrode holes (13a,13a) are symmetrically arranged about the arrangement center line P. Therefore, the four electrode holes (13a,13a,13b,13b) of the power adapter13are arranged to face the three electrode plates14(14a,14b,14c) and the ground pin15of the power plug12and are arranged to allow insertion of the electrode plates14and the ground pin15.

The power adapter13shown inFIG. 7is provided with the locking claws17serving as the locking means at positions of upper and lower ends. The locking claws17at the upper and lower ends of the power adapter13are projected substantially parallel in a direction toward the power plug (rightward in (b) ofFIG. 7) and have protrusions17awith projecting tips projecting in directions facing each other. When the electrodes (14a,14b,14c,15) serving as the connection terminals of the power plug12are inserted into the electrode holes (13a,13b) of the power adapter13, the protrusions17aare engaged with the concave portions of the locking parts12c(seeFIG. 5) located at the upper and lower positions of the power plug12, so that the power adapter13is reliably integrated with the power plug12in an attached state. In this attached state, the locking claws17above and below the power adapter13are provided with elastic members, for example, springs, so as to press the main body part12aof the power plug12in a sandwiching direction, so that the power adapter13is not detached from the power plug12.

When the power adapter13is detached from the power plug12, convex portions disposed on the locking claws17are pressed to open the facing locking claws17in opening directions, and the protrusions17aof the locking claws17are thereby released from the concave portions of the locking parts12cof the power plug12, so that the power adapter13can be detached from the power plug12.

The charging cable1according to the first embodiment is configured such that when the power adapter13is attached to the power plug12, the power adapter13can be attached even at a position rotated by 180 degrees with respect to the power plug12. Description will hereinafter be made of the configuration in which the power adapter13can be mounted at a position rotated by 180 degrees with respect to the power plug12.

FIG. 8is a cross-sectional view showing an electrode structure of the power adapter13and shows an internal structure of high-voltage electrode receptacles into which the connection terminals of the power plug12are inserted. The cross-sectional view ofFIG. 8corresponds to the rear view shown in (c) ofFIG. 7. As shown inFIG. 8, the high-voltage electrode receptacles in the power adapter13include a first/second electrode receptacle20and a second/first electrode receptacle21clamping the first electrode plate14aor the second electrode plate14bof the power plug12into an electrically connected state. A third/ground electrode receptacle22and a ground/third electrode receptacle23are also disposed for clamping the third electrode plate14cor the ground pin15of the power plug12into an electrically connected state. The third/ground electrode receptacle22and the ground/third electrode receptacle23are connected to each other in the electrode structure inside the power adapter13and are electrically connected by a connection plate24.

In the power adapter13shown in (b) ofFIG. 7, the two 100V electrode plates18(18a,18b) connected to a 100V power source and the ground pin19are projected from the surface on the left side that is the power source side. The first electrode plate18aand the second electrode plate18bof the power adapter13are electrically connected to the first/second electrode receptacle20and the second/first electrode receptacle21, respectively. Specifically, in the electrode structure inside the power adapter13, the first electrode plate18ais electrically connected to the first/second electrode receptacle20, and the second electrode plate18bis electrically connected to the second/first electrode receptacle21. In the power adapter13, the ground pin19projected on the power source side (100 V side) is electrically connected to the third/ground electrode receptacle22and the ground/third electrode receptacle23. Therefore, the third/ground electrode receptacle22and the ground/third electrode receptacle23in the power adapter13both serve as electrode receptacles on the ground side.

As shown in (c) ofFIG. 7, the power adapter13includes the two first/second electrode holes13a,13ainto which the first electrode plate14aor the second electrode plate14bof the power plug12is inserted, and the two third/ground electrode holes13b,13binto which the third electrode plate14cor the ground pin15of the power plug12is inserted. On the contact surface13e(the electrode-hole forming surface) of the power adapter13for the power plug12, the two third/ground electrode holes13b,13bare disposed at upper and lower positions on the arrangement center line P in the vertical direction. The two first/second electrode holes13a,13aare formed on the contact surface13e(the electrode-hole forming surface) at left and right symmetrical positions with respect to the arrangement center line P in the vertical direction.

The third/ground electrode hole13bhas a shape into which both the third electrode plate14cand the ground pin15of the power plug12can be inserted. The first/second electrode holes13ahave the same shape since the first electrode plate14aand the second electrode plate14bto be inserted have the same shape. The first electrode plate14aor the second electrode plate14binserted into the first/second electrode hole13ais configured to be in an electrically reliably connected state (clamped state) with respect to the first/second electrode receptacle20or the second/first electrode receptacle21that is the high-voltage electrode receptacle inside the power adapter13.

As described above, the first electrode plate14aor the second electrode plate14bof the power plug12is inserted into and guided by the first/second electrode hole13aand electrically connected to the first/second electrode receptacle20or the second/first electrode receptacle21. The third electrode plate14aor the ground electrode15of the power plug12is inserted into and guided by the third/ground electrode hole13band electrically connected to the third/ground electrode receptacle22or the ground/third electrode receptacle23.

As described above, when the power plug12is attached to the power adapter13, the first electrode plate14aor the second electrode plate14bof the power plug12is electrically connected via the first/second electrode receptacle20or the second/first electrode receptacle21to the first electrode plate18aand the second electrode plate18bserving as low-voltage electrode plates in the power adapter13and is brought into a contact state allowing heat conduction. Therefore, the temperature information from the temperature sensors16disposed near the first electrode plate14aand the second electrode plate14bis temperature information allowing detection of an abnormal temperature of the charging electric path in the power adapter13. Therefore, when an abnormal temperature in the charging electric path is detected from the temperature information from the temperature sensors16, the control part25in the control unit9transmits a pilot signal to the charging control device6of the electric propulsion vehicle2to reduce a charging current so that the power supply from the power source of the charging facility to the electric propulsion vehicle2can be reduced in this configuration.

As shown in (C) ofFIG. 7, the power adapter13has an annular skirt part13cformed to surround a tip portion on the contact side of the main body part12aof the power plug12to be connected. On the inner surface side of the skirt part13c, two position regulating protrusions13d,13dprojecting in opposite directions are formed.

FIGS. 9 and 10are diagrams for explaining a connection state between the power plug12and the power adapter13. InFIG. 9, (a) shows a state immediately before the connection between the power plug12and the power adapter13, (b) shows a state in which tip portions of the high-voltage electrode plates14(14a,14b,14c) and the ground pin15of the power plug12are inserted halfway into the electrode holes (13a,13b) of the power adapter13, and (c) shows a state when the power adapter13is completely connected (attached) to the power plug12. InFIG. 10, (a) corresponds to the state immediately before the connection of (a) ofFIG. 9, (b) corresponds to the half-inserted state of (b) ofFIG. 9, and (c) corresponds to the completely connected state of (c) ofFIG. 9.FIG. 9is a diagram showing right side surfaces of the power plug12and the power adapter13, andFIG. 10is a rear view of the power plug12and the power adapter13as viewed from below.

In the configuration of the first embodiment, the position regulating grooves12dare formed on both side surfaces of the main body part12aof the power plug12, so that the position regulating protrusions13dformed on the power adapter13(see (c) ofFIG. 7) are fit into the position regulating grooves12d. The position regulating grooves12dare disposed at positions opposite to each other on both side surfaces of the main body part12a(opposite positions rotated 180 degrees from each other). The power adapter13has the annular skirt part13cformed to surround the tip portion on the contact side of the main body part12aof the power plug12to be connected, and the position regulating protrusions13dare formed at positions opposite to each other inside the skirt part13c. These position restricting protrusions13dare configured to respectively engage with the position restricting grooves12dformed on both side surfaces of the main body part12aof the power plug12when the power adapter13is attached (connected) to the power plug12. Therefore, in the configuration of the first embodiment, the power adapter13can be connected to the power plug12only at two positions rotated 180 degrees from each other at which the position regulating protrusions13dcan engage with the position regulating grooves12d.

As described above, in the charging cable1according to the first embodiment, for example, NEMA 14-50 (rated voltage: 240 V, rated current: 50 A) in the NEMA (National Electrical Manufacturers Association) standards is used for the electrode arrangement of the connection terminals of the power plug12. Therefore, for example, the three electrode plates (14a,14b,14c) and the ground pin15are inserted in a residential power source assumed to be the residential charging facility. In such a residential power source (100 V/200 V) having a ground pin, a ground pin insertion port may be disposed on the upper side or lower side relative to an electrode insertion port. When the power plug12of the first embodiment is attached to the indoor power source A (200 V) for charging, and the ground pin insertion port is on the upper side relative to the electrode insertion port, the power plug12can be attached such that the ground pin15is located on the upper side (the state shown inFIG. 3). In this case, the power-source-side cable8from the lead-out part12bof the power plug12is arranged to be led out vertically downward.

On the other hand, when the ground pin insertion port is on the lower side relative to the electrode insertion port, the power-source-side cable8is led out upward from the power plug12, so that a force is applied to the power plug12in the direction causing disconnection from the residential power source A due to the weight of the power-source-side cable8etc. The power plug12is attached to the residential power source A (200 V) at four positions, i.e., the three electrode plates (14a,14b,14c) and the ground pin15. Furthermore, since the electrode plates and the ground pin are for high voltage and high current and therefore have a sufficient size, the power plug12is not disconnected even when such a force is applied in the direction causing disconnection from the residential power source A.

Description will be made of the case that the power plug12of the first embodiment with the power adapter13attached thereto is attached to the residential power source B (100 V) for charging. When the ground pin insertion port is on the upper side relative to the electrode insertion port, the power plug12can be attached to the power adapter13such that the ground pin15is located on the upper side (the state shown in (c) ofFIG. 9). Therefore, the power-source-side cable8from the lead-out part12bof the power plug12is arranged to be led out vertically downward.

On the other hand, when the ground pin insertion port is on the lower side relative to the electrode insertion port, the power-source-side cable8is led out upward from the power plug12in the state shown in (c) ofFIG. 9. Therefore, an unnecessary load is applied to the power adapter13integrated with the power plug12and the power source into which the power adapter13is inserted. The power adapter13is attached to the residential power source B (100 V) at three positions, i.e., the two electrode plates (18a,18b) and the ground pin19. Furthermore, the two electrode plates (18a,18b) and the ground pin19are for low voltage and low current and therefore are considerably smaller than the electrode plates (14a,14b,14c) and the ground pin15of the power plug12. If the power-source-side cable8is led out upward from the power plug12and a force is applied to the power adapter13in the direction causing disconnection from the power source, the power adapter13may be disconnected from the power source (B).

However, the charging cable1of the first embodiment allows the power plug12to be attached to the power adapter13at the opposite position rotated by 180 degrees. Even when the ground pin insertion port is on the lower side relative to the electrode insertion port, the power-source-side cable8from the lead-out part12bof the power plug12can be arranged to be led out vertically downward. This can prevent an accident such as a disconnection of the power adapter13integrated with the power plug12from the power source (B).

As described above, in the configuration of the power adapter13of the first embodiment, the high-voltage electrode holes (the third/ground electrode holes13b) are shared holes into which the third electrode plate14cand the ground pin15of the power plug12are inserted. In the configuration of the power adapter13, the third electrode plate14cand the ground pin15of the power plug12are electrically connected to the third/ground electrode receptacle22and the ground/third electrode receptacle23that are in an electrically connected state. Therefore, the ground pin15of the power plug12is electrically reliably connected to the ground pin19of the power adapter13regardless of the positions (positions rotated by 180 degrees from each other) of the power plug12attached to the power adapter13.

Therefore, when the charging cable1according to the first embodiment is used for charging, the power plug12can be attached (connected) to the power adapter13such that the lead-out part12bis always led out vertically downward.

As described above, in the charging cable1according to the first embodiment, the power plug12and the power adapter13have the ground pins (15,19) as the connection terminals, and the ground pins (15,19) are located on the upper side or the lower side relative to the connection terminals serving as the charging terminals and have a projection length set longer than the connection terminals of the charging terminals. Therefore, while the charging cable1of the first embodiment is connected to the power source (B), the power adapter13integrated with the power plug12is prevented from falling off from the power source (B).

FIG. 11is a block diagram showing a main configuration of the charging cable1of the first embodiment. As shown inFIG. 11, the control unit9of the charging cable1includes the control part25made up of a microcomputer, a power plug temperature detecting part26receiving a signal (temperature information) from the temperature sensors16disposed on the power plug12, a power-supply voltage detecting part27detecting power-supply voltage information supplied by the power plug12, the opening/closing circuit28(e.g., a relay) opening and closing a charging electric path between the power plug12and the charging coupler11, and the leakage detecting part29monitoring a current flowing through the charging electric path to detect electric leakage.

In the control part25, the temperature information is input from the power plug temperature detecting part26, and a charging operation is controlled based on the detected temperature information. When the leakage detecting part29detects electric leakage, the control part25interrupts the charging electric path via the opening/closing circuit28to stop the power supply from the power source to the electric propulsion vehicle2.

In the charging cable1of the first embodiment, the information of temperature at the power plug12, the information of the power-supply voltage supplied by the power plug12, etc. are detected by the control part25of the control unit9, and the control part15generates a pilot signal based on the detected information. The control part15is configured to transmit the generated pilot signal to the electric propulsion vehicle2connected via the vehicle-side cable10. The control part25changes, for example, a duty ratio of the pilot signal in accordance with the power-supply voltage information so as to transmit to the electric propulsion vehicle2the charging information such as a charging current to be supplied from the power source.

As described above, the configuration of the charging cable1of the first embodiment can provide the charging cable1and the power adapter used with the charging cable1compatible with power sources (100 V/200 V) in charging facilities of different standards. As described above, in the configuration of the charging cable1of the first embodiment according to the present disclosure, the power adapter13has no mechanism for converting the voltage, the electric power supplied from the power source is transmitted via the charging cable1to the electric propulsion vehicle2, and an appropriate charging operation is performed based on the electric power supplied to the electric propulsion vehicle2and the charging information.

In the description of the configuration of the first embodiment, the charging operation is controlled based on the temperature information of the power plug12and the power adapter13by using the temperature sensor16as the temperature detecting means for the power plug12; however, the present invention is not limited to this configuration. For example, in the present invention, the temperature detecting means may be used for main constituent elements such as a connection portion of the power-source-side cable8with the control unit9, the charging coupler11of the vehicle-side cable10, and/or the control unit9that is a main body, so as to control the charging operation based on pieces of the temperature information of the respective constituent elements.

Abnormal heat generated in use of the charging cable1occurs due to an incomplete contact or a tracking phenomenon in a connection portion between the power source (power outlet) of the charging facility and the power plug12, a connection portion between the charging coupler11and the connector7of the electric propulsion vehicle2, and a connection portion between connection terminals of a power line through which a charging current flows in the control unit9that is the main body. Therefore, the temperature detecting means (the temperature sensors16) are preferably disposed near the respective connection portions in the charging electric path where abnormal heat generation occurs.

As described above, in the electric propulsion vehicle2, the charging current to the battery5is controlled based on the pilot signal transmitted from the control part25in the control unit9of the charging cable1. According to the configuration of the first embodiment, when the temperature detecting means detect abnormal heat generation, the charging current can variably be set on the electric propulsion vehicle side according to the temperature detected by the temperature detecting means. Therefore, for example, when the temperature of the power plug12increases, the charging current can be reduced to continue the charging of the battery5without interruption such that a temperature rise of the power plug12is suppressed. This can result in not only a reduction in the charging time, but also an improvement in durability of a relay etc.

Alternatively, by disposing first temperature detecting means in the power plug12and/or the charging coupler11and disposing second temperature detecting means in the control unit9, the control part25can determine defect of the power plug12, the power adapter13, and/or the charging coupler11based on the output of the two first/second temperature detecting means, and this configuration leads to an improvement in reliability of the equipment.

More specifically, when the temperature detected by the temperature detecting means reaches a preset threshold value, the control part25of the control unit9can transmit a pilot signal having a changed waveform to the electric propulsion vehicle2to give notification to the electric propulsion vehicle2for reducing the charging current so as to prevent overheat of the power plug12, which enables a further improvement in safety.

Alternatively, when the temperature detected by the temperature detecting means reaches the threshold value, the control part25of the control unit9can transmit a pilot signal having a changed pulse width to the electric propulsion vehicle2to give notification to the electric propulsion vehicle2for reducing the charging current in a stepless manner so as to achieve the same effect.

Alternatively, when the temperature detected by the temperature detecting means reaches the threshold value, the control part25of the control unit9may use a pilot signal to give notification to the electric propulsion vehicle2for reducing the charging current in a stepwise manner.

Alternatively, when the temperature detected by the temperature detecting means reaches the threshold value, the control part25of the control unit9may transmit a pilot signal having a changed amplitude to the electric propulsion vehicle to give notification to the electric propulsion vehicle2for reducing the charging current.

Alternatively, the control part25of the control unit9may perform calculation with the temperature detected by the temperature detecting means and transmit to the electric propulsion vehicle2a pilot signal having an amplitude gradually changed in advance so as to prevent the temperature from reaching the threshold value, thereby giving notification to the electric propulsion vehicle2for reducing the charging current.

Furthermore, in addition to the control methods described above, a method may be adopted such that the charging electric circuit is finally interrupted when the temperature detected by the temperature detecting means reaches the threshold value.

It is noted that any of the configurations described in the embodiments can appropriately be combined to produce the excellent effects of the respective configurations.

Although the present disclosure has been sufficiently described in terms of preferable embodiments with reference to the accompanying drawings, various modifications and corrections are apparent to those skilled in the art. It should be understood that such modifications and corrections are included in the present disclosure without departing from the scope of the present disclosure according to the accompanying claims.

INDUSTRIAL APPLICABILITY

The charging cable according to the present disclosure has a simple configuration easily compatible with power sources in charging facilities of different standards and is useful as a charging cable for an electric propulsion vehicle at least equipped with a battery for running.