Hands-free conductive battery charger for an electric vehicle
First Claim
1. A conductive charging system for use with an offboard power supply and a vehicle, the vehicle having a charge coupler, an auxiliary power device, and a high-voltage direct current battery pack, the conductive charging system comprising:
- a conductive armature having a charging end and a non-charging end, wherein the charging end is electrically connected to the offboard power supply and operable for deploying into direct electrical contact with a conductive pad located on the vehicle in response to a threshold force acting on the non-charging end;
an electromagnetic relay having an inductive coil, which is positioned in electrical series with the auxiliary power device, and a second switch, which is positioned in electrical series with the charge coupler, an AC-DC converter, and the battery pack; and
a first switch positioned in electrical series between the auxiliary power device and the inductive coil, wherein the first switch is operable for closing in response to the threshold force to thereby electrically connect the auxiliary power device to the inductive coil, thereby energizing the inductive coil,wherein the second switch is configured to transition between;
a first position connecting the charge coupler to the AC-DC converter and the battery pack to thereby enable “
plug-in”
charging of the battery pack along a first charging path when the inductive coil is not energized, anda second position bypassing the charge coupler to thereby enable “
hands-free”
charging of the battery pack along a second charging path, distinct from the first charging path, when the inductive coil is energized.
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Accused Products
Abstract
A conductive charging system for use with an offboard AC or DC power supply and a plug-in vehicle includes a conductive armature, an electromagnetic relay, and a switch. The armature is connected directly to the power supply and deploys into electrical contact with the vehicle in response to the vehicle weight. The switch closes in response to the vehicle weight to connect an auxiliary power device to an inductive coil. The relay moves to a first position connecting the charge coupler to an AC-DC converter or the battery pack when the switch is open, and to a second position bypassing the charge coupler when the switch is closed. A vehicle includes the system, charge coupler, HV battery pack, auxiliary power device, and armature.
122 Citations
20 Claims
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1. A conductive charging system for use with an offboard power supply and a vehicle, the vehicle having a charge coupler, an auxiliary power device, and a high-voltage direct current battery pack, the conductive charging system comprising:
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a conductive armature having a charging end and a non-charging end, wherein the charging end is electrically connected to the offboard power supply and operable for deploying into direct electrical contact with a conductive pad located on the vehicle in response to a threshold force acting on the non-charging end; an electromagnetic relay having an inductive coil, which is positioned in electrical series with the auxiliary power device, and a second switch, which is positioned in electrical series with the charge coupler, an AC-DC converter, and the battery pack; and a first switch positioned in electrical series between the auxiliary power device and the inductive coil, wherein the first switch is operable for closing in response to the threshold force to thereby electrically connect the auxiliary power device to the inductive coil, thereby energizing the inductive coil, wherein the second switch is configured to transition between; a first position connecting the charge coupler to the AC-DC converter and the battery pack to thereby enable “
plug-in”
charging of the battery pack along a first charging path when the inductive coil is not energized, anda second position bypassing the charge coupler to thereby enable “
hands-free”
charging of the battery pack along a second charging path, distinct from the first charging path, when the inductive coil is energized. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. A method for executing a charging operation of a vehicle using an offboard power supply, the vehicle including a charge coupler configured to receive power from the offboard power supply, an auxiliary power device and a high-voltage direct current battery pack, the method comprising:
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providing a conductive charging system having a conductive armature that includes a charging end and a non-charging end, wherein the charging end is electrically connected to the offboard power supply; deploying the charging end of the conductive armature into direct electrical contact with a conductive pad located on the vehicle in response to a threshold force acting on the non-charging end, wherein the threshold force is provided by a weight of the vehicle; closing a first switch, which is positioned in electrical series between the auxiliary power device and an inductive coil, in response to the threshold force to thereby electrically connect the auxiliary power device to the inductive coil, wherein the inductive coil is positioned in electrical series with the auxiliary power device; and moving a second switch, which is positioned in electrical series with the charge coupler, an AC-DC converter, and the battery pack, of an electromagnetic relay having the inductive coil to either of; a first position connecting the charge coupler to the AC-DC converter and the battery pack to thereby enable “
plug-in”
charging of the battery pack along a first charging path when the inductive coil is not energized, anda second position bypassing the charge coupler to thereby enable “
hands-free”
charging of the battery pack along a second charging path, distinct from the first charging path, when the inductive coil is energized, and wherein the second switch is moved from the first position to the second position by a threshold inductance generated across the inductive coil when the first switch is closed. - View Dependent Claims (14, 15, 16, 17, 18, 19, 20)
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Specification