Charging system for a vehicle

• US 5,049,802 A
• Filed: 03/01/1990
• Issued: 09/17/1991
• Est. Priority Date: 03/01/1990
• Status: Expired due to Fees

• Current Assignee: FMC Corporation
• Original Assignee: Caterpillar Industrial Inc (Caterpillar Incorporated)
• Inventors: Paine, John C., Mintus, Robert T.
• Primary Examiner(s): Hickey, R. J.
• Application Number:
  US07/487,001
• Time in Patent Office: 565 Days
• Field of Search: 320/90, 320/2, 320/5, 320/56, 320/44, 320/8
• US Class Current: 320/107
• CPC Class Codes: B60L 2200/44 Industrial trucks or floor conveyors
• CPC Class Codes: B60L 2240/421 Speed
• CPC Class Codes: B60L 2240/429 Current
• CPC Class Codes: B60L 2240/60 Navigation input
• CPC Class Codes: B60L 2240/72 Charging station selection relying on external data
• CPC Class Codes: B60L 2250/10 by alarm
• CPC Class Codes: B60L 2250/16 by display
• CPC Class Codes: B60L 2260/32 Auto pilot mode
• CPC Class Codes: B60L 3/0069 relating to the isolation, e.g. ground fault or leak current
• CPC Class Codes: B60L 3/04 Cutting off the power supply under fault conditions protective devices and circuit arrangements in general H01H; H02H
• CPC Class Codes: B60L 50/52 characterised by DC-motors
• CPC Class Codes: B60L 50/66 Arrangements of batteries
• CPC Class Codes: B60L 53/14 Conductive energy transfer
• CPC Class Codes: B60L 53/305 Communication interfaces
• CPC Class Codes: B60L 58/14 Preventing excessive discharging
• CPC Class Codes: G05D 1/0225 involving docking at a fixed facility, e.g. base station or loading bay parking aids B62D15/027
• CPC Class Codes: G05D 1/0236 in combination with a laser lasers per se H01S
• CPC Class Codes: G05D 1/028 using a RF signal
• CPC Class Codes: H02J 7/0042 characterised by the mechanical construction
• CPC Class Codes: Y02P 90/60 Electric or hybrid propulsion means for production processes
• CPC Class Codes: Y02T 10/64 : Electric machine technologies in electromobility
• 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 10/72 : Electric energy management in electromobility
• CPC Class Codes: Y02T 90/12 : Electric charging stations
• CPC Class Codes: Y02T 90/14 : Plug-in electric vehicles
• CPC Class Codes: Y02T 90/16 : Information or communication technologies improving the operation of electric vehicles

Abstract

Automated charging systems for vehicles having rechargeable batteries are in common use today. Such systems typically have exposed contacts or the need for additional circuitry to move the contacts. The subject system includes circuitry which allows the charge receiving member to be only connected to the battery during charging. The charging system produces a charging signal in response to a low battery. A microprocessor receives the charging signal and responsively produces a "pulse" signal. A second transistor switch receives the "pulse" signal and responsively energizes a charging contactor coil. In response to the charging contactor coil being energized, contacts controllably block power from the battery to the motor and pass power from the receiving member to the battery.

Claims

1. A charging system having a charging location for a vehicle, said vehicle including a rechargeable battery normally controllably connected to a vehicle motor, comprising:

a charge receiving member controllably connectable to said battery;

means for determining the position of said charging location;

vehicle control means for positioning said vehicle based on said determined position at said charging location and producing a responsive charge control signal; and

logic means for receiving said charge control signal and automatically disconnecting said vehicle motor from said battery, and connecting said charge receiving member to said battery in response to receiving said charge control signal, and thereafter charging said vehicle battery.

2. A charging system as set forth in claim 1, wherein said charge receiving member is disconnected from said battery except when said charge control signal is present.

3. A charging system as set forth in claim 1, wherein said charge receiving member is connected to said vehicle and is maintained substantially free from movement relative to said vehicle.

4. A charging system as set forth in claim 1, wherein said charging location includes a charge producing member connectable to said charge receiving member and maintained substantially free from movement relative to said charging location.

5. A charging system as set forth in claim 1, wherein said vehicle includes a battery monitor means for sensing the state of charge of said battery and producing a low battery signal in response to the state of charge being less than a predetermined value, and said vehicle control means receives said low battery signal and responsively positions said vehicle at said charging location.

6. A charging system as set forth in claim 1, wherein said vehicle includes a detecting means for sensing a ground fault connection and responsively disconnecting said charge receiving member from said battery.

7. A charging system as set forth in claim 1, wherein said vehicle includes switching means for manually connecting said charge receiving member to said battery.

8. A charging system for a vehicle, said vehicle including a rechargeable battery normally controllably connected to a vehicle motor, comprising:

a charge receiving member connected to said vehicle;

a battery having positive and negative terminals, said negative terminal being connected to ground;

a contactor having at least first and second contacts, said first contact being normally open and being connected between said charge receiving member and said positive terminal of said battery and said second contact being normally closed and being connected between said motor and said positive battery thermal.

9. A charging system as set forth in claim 8, including a charging contactor coil to control said contacts and a normally open charge control switch, said charging contactor coil having first and second ends, said first end being connected to said positive battery terminal through said charge control switch and said second end being connected to ground.

10. A charging system as set forth in claim 9, wherein said contactor also includes third and fourth contacts, said third contact being normally open and being connected between said receiving member and ground and said fourth contact being normally closed and being connected between said motor and ground.

11. A charging system as set forth in claim 8, wherein said charge receiving member is maintained substantially free from movement relative to said vehicle.

12. A charging system as set forth in claim 8, including a battery monitor connected between said positive terminal of said battery and at least one of said first and second contacts.

13. A charging system as set forth in claim 8, including a charging location having a charge producing member, said charge producing member being maintained substantially free from movement relative to said charging location.

14. A method for charging a vehicle at a charging location, said vehicle including a rechargeable battery controllably connected to a vehicle motor and a charge receiving member, comprising the steps of:

determining the position of said charging location;

positioning said vehicle based on said determined position at said charging location and producing a responsive charge control signal; and

receiving said charge control signal and automatically disconnecting said vehicle motor form said battery, and connecting said charge receiving member to said battery in response to receiving said charge control signal, and thereafter charging said vehicle battery.

15. A method, as set forth in claim 14, including the step of sensing an abnormal ground connection during charging and responsively disconnecting said charge receiving member from said battery.

16. A method, as set forth in claim 14, including the steps of sensing a voltage potential on said charge receiving member and automatically disconnecting said motor from said battery when said vehicle is not charging.

17. A charging system having a charging location for a vehicle, said vehicle including a rechargeable battery normally controllably connected to a vehicle motor, comprising:

a charge receiving member controllably connectable to said battery;

vehicle control means for positioning said vehicle at said charging location and producing a responsive charge control signal;

sensing means for producing a warning signal in response to detecting a voltage potential on said charge receiving member when said vehicle is not charging; and

logic means for receiving said charge control signal and responsively disconnecting said vehicle motor from said battery and connecting said charge receiving member to said battery, and receiving said warning signal and automatically disconnecting said motor from said battery in response to receiving said warning signal.

18. A method for charging a vehicle, said vehicle including a rechargeable battery controllably connected to a vehicle motor and a charge receiving member, comprising the steps of:

positioning said vehicle at a charging location and producing a responsive charge control signal;

receiving said charge control signal and responsively disconnecting said battery from said vehicle motor and connecting said charge receiving member to said battery;

sensing an abnormal ground connection during charging and responsively disconnecting said charge receiving member from said battery; and

sensing a voltage potential on said charge receiving member and automatically disconnecting said motor from said battery when said vehicle is not charging.

19. A charging system having a charging location for a vehicle, said vehicle including a rechargeable battery normally controllably connected to a vehicle motor, comprising:

a charge receiving ;

emmber controllably connectable to said battery;

vehicle control means for producing a charge control signal in response to said vehicle being at said charging location;

logic means for receiving said charge control signal and for responsively producing a pulse signal and disconnecting said vehicle motor from said battery; and

charging control means for receiving said pulse signal and responsively connecting said charge receiving member to battery.