Battery pack charging system with manually maneuvered charge head

• US 8,373,389 B2
• Filed: 01/22/2010
• Issued: 02/12/2013
• Est. Priority Date: 01/22/2010
• Status: Active Grant

• Current Assignee: Berkley C. Badger
• Original Assignee: Berkley C. Badger
• Inventors: Badger, Berkley C.
• Primary Examiner(s): Dunn, Drew A
• Assistant Examiner(s): PELTON, NATHANIEL R
• Application Number:
  US12/657,552
• Publication Number:
  US 20110181241A1
• Time in Patent Office: 1,117 Days
• Field of Search: 320/104, 320/109
• US Class Current: 320/109
• 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: B60L 53/65 involving identification of vehicles or their battery types
• CPC Class Codes: B60L 53/665 Methods related to measuring, billing or payment
• CPC Class Codes: B60L 58/25 by controlling the electric load
• CPC Class Codes: H01M 10/42 Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells H01M10/60 takes precedence
• CPC Class Codes: H01M 10/48 Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals, H01M50/569
• CPC Class Codes: H01M 10/486 for measuring temperature
• CPC Class Codes: H02J 7/0042 characterised by the mechanical construction
• 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 charging system which is particularly suitable for recharging the batteries of electrically powered motor vehicles using a charge head with multiple contacts that mate with an array of charge receiving electrodes onboard the vehicle being recharged. The charge head is supported from overhead, and may, using a power assisted system, be lowered, into place against the array of charge receiving electrodes onboard the vehicle. Switches may be spaced apart so that, like the grasping elements of the handle, use of both hands is required. The charge head causes breaking of series connections of batteries within the vehicle so that individual batteries may be charged in parallel. A battery temperature monitor is provided. An annunciator locally or remotely signals errors or indicates completion of charge. Payments are accepted near the charge head, thereby allowing for commercial operation.

Claims

1. A system for recharging a battery of an electrically powered vehicle, comprising:

a) a charging head comprising a plurality of charging electrodes, each adapted for selective electrical interconnection with a corresponding, mating charge-receiving electrode in an electrically powered vehicle having a battery to be recharged, each of said charging electrodes being operatively connected to a source of electrical power;

b) a support operatively connected to said charging head and adapted to suspend and facilitate selectively positioning said charging head into a charge transferring relationship with said electrically powered vehicle, wherein said support comprises an overhead suspension system further comprising an apparatus for selectively maneuvering said charge head at least downwardly and laterally, wherein said overhead suspension system comprises a plurality of rigid links collectively comprising at least three swivel connections, each of said at least three swivel connections having a respective axis of rotation, each respective axis of rotation being mutually orthogonal to one another, whereby the overhead suspension support provides at least six degrees of freedom of motion of said charge head; and

c) a charge monitoring system disposed between said charging head and said source of electrical power, said charge monitoring system containing at least one device selected from the list;

an electrical current sensor, an electrical voltage sensor, a rate-of-charge monitor, a temperature monitor, a rate-of-charge controller and means for electrically disconnecting said charging head from said battery responsive to a sensed condition.

2. The system for recharging a battery of an electrically powered vehicle as recited in claim 1, further comprising:

d) a maneuvering handle coupled to said charge head, comprising;

i) a first grasping element adapted for gripping by a first hand of an operator;

ii) a second grasping element spaced apart from said first grasping element and adapted for gripping by an opposite hand of said operator;

whereby an operator must use both hands to grasp both said first grasping element and said second grasping element.

3. The system for recharging a battery of an electrically powered vehicle as recited in claim 2, further comprising:

e) a hydraulic assist system operatively connected to said overhead suspension system and to said charging head, said hydraulic assist system comprising;

i) a hydraulic cylinder supported from said overhead support;

ii) a piston operatively connected to said charge head;

iii) a source of pressurized hydraulic fluid operatively connected to said piston; and

iv) a control disposed between said piston and said source of pressurized hydraulic fluid;

whereby said charge head may selectively be raised and lowered by said piston in response to said control.

4. The system for recharging a battery of an electrically powered vehicle as recited in claim 3, wherein said control comprises at least one control selected from the group:

a pushbutton;

a hydraulic valve, and at least one dead man control operatively connected to said hydraulic assist system.

5. The system for recharging a battery of an electrically powered vehicle as recited in claim 4, wherein said at least one dead man switch comprises:

f) a first dead man switch disposed on said maneuvering handle proximate said first grasping element for actuation by said first hand of said operator; and

g) a second dead man switch disposed on the maneuvering handle proximate said second grasping element for actuation by said opposite hand of said operator;

actuation of both said first dead man and said second dead man switch being required to actuate said hydraulic assist system.

6. The system for recharging a battery of an electrically powered vehicle as recited in claim 1, wherein said power source comprises a source of DC voltage.

7. The system for recharging a battery of an electrically powered vehicle as recited in claim 1, wherein said plurality of charging electrodes comprises at least four individual charging electrodes.

8. The system for recharging a battery of an electrically powered vehicle as recited in claim 1, wherein each one of said plurality of charging electrodes has a flat conductive charge transmitting charging surface.

9. The system for recharging a battery of an electrically powered vehicle as recited in claim 1, further comprising:

d) an alignment element disposed on said charging head adapted to interactively engage a mating alignment element of said electrically powered vehicle such that said plurality of charging electrodes of said charging head engages an array of charge-receiving electrodes disposed in said electrically powered vehicle in a predetermined direction and orientation relative thereto.

10. The system for recharging a battery of an electrically powered vehicle as recited in claim 9, wherein said alignment element comprises at least two pins each having a tapered blunt exposed end.

11. The system for recharging a battery of an electrically powered vehicle as recited in claim 1, further comprising:

d) a monitoring system operatively connected to a at least one of said source of electrical power and said battery of said electrically powered vehicle, said monitoring system disposed to perform at least one function selected from the group;

to sense progress of charging of batteries connected to said charging electrode system, and to discern and report completion of charging of said batteries connected to said charging electrode system.

12. The system for recharging a battery of an electrically powered vehicle as recited in claim 11, wherein said monitoring system comprises a visual indicator disposed to annunciate completion of charging.

13. The system for recharging a battery of an electrically powered vehicle as recited in claim 11, wherein said monitoring system comprises means for generating a wireless communications signal to annunciate completion of charging.

14. The system for recharging a battery of an electrically powered vehicle as recited in claim 13, wherein said means for generating a wireless communications signal comprises apparatus for generating a cellular telephone call.

15. The system for recharging a battery of an electrically powered vehicle as recited in claim 14, wherein said means for generating a wireless communications signal comprises apparatus transmitting a message to a personal digital assistant.

16. The system for recharging a battery of an electrically powered vehicle as recited in claim 11, wherein said monitoring system further comprises apparatus disposed to monitor temperature of at least one of the group:

the batteries being charged by said charging electrode system, an interconnecting cable, a cable connection, and said charging electrode system.

17. The system for recharging a battery of an electrically powered vehicle as recited in claim 16, wherein the monitoring system includes a thermistor.

18. The system for recharging a battery of an electrically powered vehicle as recited in claim 17, wherein said monitoring system further comprises a controller to vary a rate of charge being delivered by said system for recharging a battery responsive to battery temperature sensed by said thermistor.

19. The system for recharging a battery of an electrically powered vehicle as recited in claim 1, further comprising:

d) a security system disposed to sense identity of a vehicle being connected to said system for recharging a battery.

20. The system for recharging a battery of an electrically powered vehicle as recited in claim 1, further comprising a payment acceptance arrangement disposed to control delivery of electrical power through said system for recharging a battery, wherein said payment acceptance arrangement inhibits delivery of electrical power until payment is made.

21. The system for recharging a battery of an electrically powered vehicle as recited in claim 1, further comprising a protective hood arrangement for covering each charging electrode when each charging electrode is not in charge transferring relation to an electrode being charged by the charging electrode system.

22. The system for recharging a battery of an electrically powered vehicle as recited in claim 1, wherein said source of electrical power comprises a power converter system adapted to receive input electrical power as alternating current and to convert said alternating current to direct current.

23. The system for recharging a battery of an electrically powered vehicle as recited in claim 22, wherein said power converter system transforms said alternating current at an input voltage to direct current at a voltage lower than said input voltage.