Automatic electric vehicle charging system

• US 5,461,298 A
• Filed: 01/15/1993
• Issued: 10/24/1995
• Est. Priority Date: 01/15/1993
• Status: Expired due to Term

• Current Assignee: Delphi Technologies, Inc. (BorgWarner Incorporated)
• Original Assignee: Hughes Aircraft Company (Rtx Corporation)
• Inventors: Brown, Daniel P., Klatt, Robert W., Lara, Jesus D., Palombo, Mario P.
• Primary Examiner(s): Wong, Peter S.
• Assistant Examiner(s): TSO, EDWARD H
• Application Number:
  US08/006,065
• Time in Patent Office: 1,012 Days
• Field of Search: 320/2, 320/48, 320/61, 74/479 B, 74/479 BP, 395/80, 395/82, 395/93, 395/86, 901/2, 901/16, 901/17, 901/18, 901/23, 901/47
• US Class Current: 320/109
• CPC Class Codes: B60L 2250/20 by driver identification
• CPC Class Codes: B60L 3/0046 relating to electric energy storage systems, e.g. batteries or capacitors
• CPC Class Codes: B60L 3/0069 relating to the isolation, e.g. ground fault or leak current
• CPC Class Codes: B60L 53/16 Connectors, e.g. plugs or sockets, specially adapted for charging electric vehicles
• CPC Class Codes: B60L 53/30 Constructional details of charging stations
• CPC Class Codes: B60L 53/305 Communication interfaces
• CPC Class Codes: B60L 53/36 by positioning the vehicle
• CPC Class Codes: B60L 53/37 using optical position determination, e.g. using cameras
• CPC Class Codes: B60L 53/65 involving identification of vehicles or their battery types
• CPC Class Codes: G07F 15/005 dispensed for the electrical charging of vehicles electrical charging as such, B60L50/00
• CPC Class Codes: H01M 10/44 Methods for charging or discharging circuits for charging H02J7/00
• 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
• CPC Class Codes: Y02T 90/16 Information or communication technologies improving the operation of electric vehicles
• CPC Class Codes: Y02T 90/167 Systems integrating technologies related to power network operation and communication or information technologies for supporting the interoperability of electric or hybrid vehicles, i.e. smartgrids as interface for battery charging of electric vehicles [EV] or hybrid vehicles [HEV]
• CPC Class Codes: Y04S 30/14 Details associated with the interoperability, e.g. vehicle recognition, authentication, identification or billing

Abstract

A system and method for automatically docking a vehicle with respect to a charge station. First, the system and method automatically aligns a charge probe arm 40 with respect to a vehicle charge port 50. Next, the system and method automatically establish a power connection between the probe 40 and port 50. Next, charging power is delivered through the connection to charge the electric power storage devices of the vehicle. Finally, the charging connection is automatically disconnected by disconnecting the probe 40 from the port 50 once charging is completed.

Claims

1. A method for docking an electric passenger vehicle with an electric charging station for recharging electric power storage devices in said electric vehicle, said method comprising the steps of:

aligning said electric vehicle with respect to said charging station;

automatically aligning a charging probe on said charging station with a charging receptacle on said electric vehicle;

automatically electrically connecting said charging probe with said charging receptacle;

automatically delivering charging power through said charging probe and charging receptacle connection to charge said storage devices; and

automatically disengaging said charging probe from said charging receptacle when said storage devices are fully charged;

transmitting at least two vehicle alignment beams in a substantially horizontal plane from said electric vehicle toward said charging station, said beams aligned so as to form an intersecting interference pattern, said interference pattern providing a visual indication of whether said alignment beams are hitting said charging station at different points or at the same point;

viewing said interference pattern on said charging station;

moving said electric vehicle toward said charging station while said interference pattern indicates each beam is hitting said charging station at divergent points; and

ceasing movement of said electric vehicle toward said charging station when said interference pattern indicates each beam is hitting said charging station at the same point.

2. A method as set forth in claim 1 further including the steps of:

transmitting at least two parallel probe alignment beams from said charging receptacle toward said charging probe;

articulating said charging probe to establish light beam communication between said probe alignment beams and corresponding probe alignment beam photodetectors located on said charging probe via corresponding beam alignors located on said charging probe; and

ceasing articulation of said charging probe when communciation is established from said probe alignment beams through said corresponding beam alignors to said corresponding alignment beam photodetectors.

3. A method as set forth in claim 1 further including the steps of:

transmitting vehicle-specific information from said vehicle to said charging station;

extending said charging probe to a vehicle-specific starting position, said vehicle-specific starting position being a predetermined spacial position of said probe arm with respect to said vehicle from which said step of automatically aligning said probe arm with respect to said charge receptacle begins; and

delivering a vehicle-specific rate of charge and a vehicle-specific capacity of charge to said storage devices upon having automatically connected said charging probe to said charging receptacle.

4. A method as set forth in claim 3 wherein said charging probe has a charge plate which engages said charging port and an articulable charge probe arm for spatially articulating said charge plate with respect to said charging receptacle, and wherein said charge probe arm has at least two alignment beam photodetectors and wherein said charge plate includes at least two beam alignors, wherein the step of automatically aligning said charging probe with said charging receptacle comprises:

transmitting at least two parallel probe alignment beams from said charging receptacle toward said charging probe;

articulating said charging probe to establish light beam communication between said probe alignment beams and said probe alignment beam photodetectors via said beam alignors; and

ceasing articulation of said charging probe when light communication is established from said probe alignment beams through said corresponding beam alignors to said corresponding alignment beam photodetectors.

5. A method as set forth in claim 1 wherein said charging probe includes a first mechanism comprising a linearly translatable collar slidingly mounted on a carrier, a second mechanism comprising said carrier being rotatably mounted within a journal, and a third mechanism comprising a linearly translatable inner sleeve slidingly mounted within an outer sleeve, wherein said step of articulating said charging probe with respect to said charging receptacle includes:

moving said collar along said carrier to impart radial motion to said charging probe;

rotating said carrier within said journal to impart rotational motion to said charging probe; and

moving said inner sleeve within said outer sleeve to impart longitudinal motion to said charging probe.

6. A cooperative docking system for an electric passenger vehicle, said system comprising:

charging station means for charging said electric vehicle, said charging station means comprising power means for generating charging power and probe means for electrically connecting said electric vehicle with said power means and for delivering said charging power to said electric vehicle;

vehicle alignment means for aligning said electric vehicle with respect to said charging station;

probe alignment means for aligning said probe means with respect to said electric vehicle; and

sequence initiation means for initiating a docking sequence wherein said vehicle alignment means, said probe alignment means, said probe means and said power means cooperate to align said electric vehicle with said charging station, align said probe with said electric vehicle, establish electrical charging power delivery through said probe to said electric vehicle to charge said electric vehicle, and discontinue said delivery of charging power to said electric vehicle when said electric vehicle is fully charged,

wherein said vehicle alignment means comprises at least two vehicle alignment beams transmitted in a substantially horizontal plane from said electric vehicle toward said charging station, said beams aligned so as to form an intersecting interference pattern said interference pattern providing a visual indication of whether said alignment beams are hitting said charging station at different points or at the same point, wherein a driver of said electric vehicle can view said interference pattern on said charging station and can move said electric vehicle toward said charging station while said interference pattern indicates each beam is hitting said charging station at divergent points and can cease movement of said electric vehicle toward said charging station when said interference pattern indicates each beam is hitting said charging station at the same point.

7. A system as set forth in claim 6 wherein said probe means comprises an articulable arm, and wherein said probe alignment means comprises:

at least two alignment beams emitted from said electric vehicle toward said articulable arm;

at least two photodetectors located on said articulable arm near an end of said arm furthest away from said electric vehicle; and

at least two alignor passages located on said articulable arm near an end closest to said electric vehicle, where said articulable arm is articulated until light communication is established between said alignment beams and said photodetectors via said alignor passages.

8. A system as set forth in claim 7 wherein said alignment means further comprises logic means for executing a probe alignment search sequence, wherein said search sequence comprises:

transmitting said alignment beams from said electric vehicle toward said articulable arm;

articulating said articulable arm to establish light beam communication between said alignment beams and said photodetectors via said alignor passages; and

ceasing articulation of said articulable arm when light communication is established from said alignment beams through said alignor passages to said photodetectors.

9. A system as set forth in claim 8 wherein said articulable arm comprises:

an inner sleeve slidably mounted within an outer sleeve, wherein sliding said inner sleeve within said outer sleeve imparts z-axis articulation;

a housing rotatably mounted within a fixed journal, wherein rotating said housing within said journal imparts rotational articulation;

a collar slidably mounted on a carrier, wherein sliding said collar along said carrier imparts radial articulation;

a pivot ball pivotally mounted within said housing; and

a linkage pivotally connected on one end to said collar and connected on the other end to said pivot ball;

said outer sleeve connected to the side of said pivot ball opposite the side said collar is linkably connected to said pivot ball, said carrier connected to said housing on a side of said housing adjacent to the side of said pivot ball where said collar is linkably connected, where sliding said inner sleeve within said outer sleeve translates said inner sleeve along the z-axis with respect to said outer sleeve and said housing, where rotating said housing within said journal rotates said inner and outer sleeves with respect to said journal, and wherein sliding said collar along said carrier sweeps said inner and outer sleeves in an arc with respect to said journal.

10. A system as set forth in claim 7 wherein said alignment beams are pulsed at a predetermined rate to produce a pulsed light signal and wherein said photodetectors are tuned to detect said pulsed light signal, and wherein said photodetectors generate an alignment signal when said pulsed light signals are communicated through said alignor passages to said photodetectors and wherein said photodetectors do not generate an alignment signal if light not of said predetermined pulsed rate is communicated to said photodetectors, whereby said probe alignment means is made resistant to generating false alignment signals due to ambient light.

11. A system as set forth in claim 6 wherein said sequence initiation means comprises a sequence initiation transmitter located on said electric vehicle and a sequence initiation receiver located on said charging station.