Charging Device for Charging an Electric Vehicle at a Charging Station

• US 20150210176A1
• Filed: 04/02/2015
• Published: 07/30/2015
• Est. Priority Date: 10/22/2012
• Status: Active Grant

• Current Assignee: Kostal Kontakt Systeme Gmbh
• Original Assignee: Kostal Kontakt Systeme Gmbh
• Inventors: Welschholz, Joerg, Hauptenbuchner, Siegfried, Scherer, Thomas, Schroeder, Georg, Schubert, Matthias, Drees, Roland
• Granted Patent: US 9,725,002 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B60L 53/14 Conductive energy transfer
• CPC Class Codes: B60L 53/16 Connectors, e.g. plugs or sockets, specially adapted for charging electric vehicles
• CPC Class Codes: B60L 53/35 Means for automatic or assisted adjustment of the relative position of charging devices and vehicles
• CPC Class Codes: H01M 2220/20 Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01R 13/193 Means for increasing contact pressure at the end of engagement of coupling part , e.g. zero insertion force or no friction
• CPC Class Codes: H01R 13/4534 Laterally sliding shutter
• CPC Class Codes: H01R 13/6315 allowing relative movement between coupling parts, e.g. floating connection for coupling devices specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures, H01R12/91 takes precedence
• CPC Class Codes: H02J 2310/48 for electric vehicles [EV] or hybrid vehicles [HEV]
• CPC Class Codes: H02J 50/90 involving detection or optimisation of position, e.g. alignment
• CPC Class Codes: H02J 7/02 for charging batteries from ac mains by converters
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 90/12 Electric charging stations
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles

Abstract

A charging system for charging an electric vehicle at a charging station includes a charge module at the charging station and a charge module at the vehicle. The charge modules include electric contact elements which can be interconnected together. The charging system includes an automatic positioning device configured to move the charging station charge module relative to the vehicle charge module to align and join the charge modules together. The charging system includes an automatic feed device configured to enable the contact elements of the charging station charge module to connect to the contact elements of the vehicle charge module when the charge modules are joined together. The contact elements of the charge modules are configured such that the contact elements can connect to each other without overriding a contact force.

Claims

1. An electric vehicle charging system comprising:

a first charge module having a first electrical contact element including a guide sleeve slidable along a contact pin;

a second charge module having a second electrical contact element including contact plates coupled together by a spring, wherein a distance of the contact plates between one another depends on a contact force of the spring and the contact force depends on a position of the spring; and

wherein a position of the guide sleeve with respect to the second contact element affects the position of the spring and thereby affects the distance of the contact plates between one another such that the contact pin can be inserted between the contact plates without friction when the charge modules are joined together.

2. The system of claim 1 wherein:

the first and second charge modules are joined together in a form fitting manner after being joined by a latch that can be actuated.

3. The system of claim 1 wherein:

the first and second charge modules further include interacting centering members for enabling the charge modules to be joined together.

4. The system of claim 3 wherein:

the first charge module further includes positioning members for enabling the first and second charge modules to be joined together.

5. The system of claim 1 wherein:

the contact pin is a flat connector pin.

6. The system of claim 1 wherein:

the second charge module further includes a protective cap that closes a housing of the second charge module, wherein the protective cap opens upon the first charge module being joined to the second charge module.

7. The system of claim 1 wherein:

the first charge module is of a charging station and the second charge module is of an electric vehicle.

8. The system of claim 1 wherein:

a position of the first charge module relative to the second charge module to join the charge modules together is performed using an automatic positioning device.

9. The system of claim 8 wherein:

the position of the first charge module relative to the second charge module is movable along three mutually perpendicular spatial axes (x, y, z).

10. The system of claim 1 wherein:

the first contact element is fed from the first charge module upon activation of an automatic feed device when the charge modules are joined together to enable the first contact element to be connected to the second contact element.

11. The system of claim 1 wherein:

the second contact element further includes a contact carrier having a chamfer connected to the spring, wherein when the guide sleeve is engaged into the chamfer the position of the spring is such that the spring generates a contact force which pushes the contact plates apart from one another thereby forming an intermediate space between the contact plates for receiving the contact pin therein without friction.

12. The system of claim 11 wherein:

when the guide sleeve is disengaged from the chamfer the position of the spring is such that the spring generates a contact force which is insufficient for pushing the contact plates apart from one another thereby enclosing the intermediate space between the contact plates.

13. A charging system for charging an electric vehicle at a charging station, the charging system comprising:

a first charge module of a charging station, the first charge module having a first electrical contact element including a contact pin and a guide sleeve, wherein the guide sleeve is slidable along a contact pin;

a second charge module of an electric vehicle, the second charge module having a second electrical contact element including contact plates, a spring, and a contact carrier, wherein the contact plates ae coupled together by the spring and the spring is coupled to the contact carrier, a distance of the contact plates between one another depends on a contact force of the spring, the contact force depends on a position of the spring, and the position of the spring depends on a position of the contact carrier; and

wherein a position of the guide sleeve along the contact pin with respect to the second contact element affects the position of the contact carrier thereby affecting the position of the spring and the distance of the contact plates between one another such that the contact pin can be inserted between the contact plates without friction when the charge modules are joined together.

14. The system of claim 13 wherein:

a position of the first charge module relative to the second charge module to join the charge modules together is performed using an automatic positioning device at the charging station.

15. The system of claim 13 wherein:

the first contact element is fed from the first charge module upon activation of an automatic feed device at the charging station when the charge modules are joined together to enable the first contact element to be connected to the second contact element.

16. The system of claim 13 wherein:

when the guide sleeve engages the contact carrier the position of the spring is such that the spring generates a contact force which pushes the contact plates apart from one another thereby forming an intermediate space between the contact plates for receiving the contact pin therein without friction.

17. The system of claim 16 wherein:

when the guide sleeve is disengaged from the contact carrier the position of the spring is such that the spring generates a contact force which is insufficient for pushing the contact plates apart from one another thereby enclosing the intermediate space between the contact plates.