Overhead power cable management system

• US 9,457,674 B2
• Filed: 09/21/2011
• Issued: 10/04/2016
• Est. Priority Date: 09/25/2009
• Status: Expired due to Fees

• Current Assignee: Control Module, Inc.
• Original Assignee: Control Module, Inc.
• Inventors: Bianco, James S., Fahy, John
• Primary Examiner(s): Isla Rodas, Richard
• Assistant Examiner(s): DIBENEDETTO, MICHAEL N
• Application Number:
  US13/238,578
• Publication Number:
  US 20120048983A1
• Time in Patent Office: 1,840 Days
• Field of Search: 242/155.R, 242/388.9, 242/389, 242/390, 242/390.1, 242/390.2, 242/417, 242/417.1, 242/417.2, 242/417.3, 226/4, 226/12, 191/8, 191/12.R, 191/23.A, 222/538, 254/208, 254/242, 254/265, 320/109, 320/111, 439/1, 439/6, 439/32, 439/131, 439/527, 439/531, 439/445, 439/544, 439/545
• US Class Current: 1/1
• CPC Class Codes: B60L 2240/28 Door position
• CPC Class Codes: B60L 2240/32 Driving direction
• CPC Class Codes: B60L 53/16 Connectors, e.g. plugs or sockets, specially adapted for charging electric vehicles
• CPC Class Codes: B60L 53/18 Cables specially adapted for charging electric vehicles
• CPC Class Codes: B60L 53/305 Communication interfaces
• CPC Class Codes: B60L 53/31 Charging columns specially adapted for electric 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: G07F 15/005 dispensed for the electrical charging of vehicles electrical charging as such, B60L50/00
• 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 power cable which connects to charge the battery power supply of an electric vehicle is suspended at a height generally above the vehicle and is automatically retractable. The operation of the power cable is automatically managed to provide a slack-free condition of the cable when the cable is moved in the extending and the retracting directions. The cable connector is easily accessible and the connector is positionable for ease of connection with the vehicle battery charging terminal. The cable management system for extending and retracting the overhead power cable employs a drive mechanism and a clutch assembly which are electronically controlled.

Claims

1. A power cable management system comprising:

a power cable;

a motor which drives a shaft;

a drive pulley mounted to said shaft and receiving said power cable;

a clutch assembly operatively engageable with said shaft and transformable between a drive mode and a release mode;

a controller which selectively controls a mode of said clutch assembly;

a drive wheel operatively connected to said clutch assembly;

a continuous belt driven by said drive wheel;

a trolley mounting an idler pulley receiving said power cable and connected to said belt wherein said trolley is positionable by said belt;

so that said power cable is moved in either an extending or retracting direction and when said clutch assembly is in a drive mode, said drive pulley, said trolley and said idler pulley are driven wherein said trolley and said idler pulley are correspondingly displaced to maintain a substantially continuous condition of said power cable when said power cable is moved in the extending and the retracting directions, and when said clutch assembly is in a release mode, said power cable can be pulled for extension.

2. The cable management system of claim 1, wherein said clutch assembly further comprises a pair of members having axially extending, angularly spaced teeth which define recesses and which axially mesh in the drive mode.

3. The cable management system of claim 2, wherein said teeth and recesses have substantially arcuate angular widths and said teeth are received in opposing recesses and the angular widths of the recesses are larger than the angular widths of said received teeth.

4. The cable management system of claim 1, further comprising a belt drive shaft which is driven by said pulley drive shaft, when said clutch is in a drive mode.

5. The cable management system of claim 4, wherein said belt drive shaft and pulley drive shaft are parallel and said shafts are rotatably coupled by a chain sprocket assembly.

6. The cable management system of claim 1, wherein said clutch assembly comprises a solenoid having an arm which pivotally moves a lever.

7. The cable management system of claim 6, wherein said lever has an end portion which engages a drive flange mounted to the pulley drive shaft, and said lever is engageable with said flange for transforming the clutch to a release mode.

8. The cable management system of claim 1, wherein said belt movably connects between a belt drive wheel and an idler wheel.

9. The cable management system of claim 1, wherein said trolley moves in a longitudinal direction and comprises a platform supported by rollers, and said idler pulley is mounted to said platform and rotates about an axis orthogonal to said longitudinal direction, said trolley being secured to said belt.

10. The cable management system of claim 1, further comprises a magnet mounted at a selected position of said belt and further comprising a Hall effect sensor for sensing the position of said magnet and defining a home position of said power cable.

11. The cable management system of claim 10, wherein said controller generates signals to retract said power cable to the home position.

12. The cable management system of claim 1, wherein upon generation of command signals from said controller, said power cable is driven to a usage position and said clutch is transformed to a release mode to allow said cable to be manually pulled to an extended position.

13. The cable management system of claim 1, further comprising a housing enclosing at least a portion of said power cable, said pulley, said motor, said clutch assembly, said controller, said belt and said trolley.

14. The cable management system of claim 13, wherein said housing further comprises a bottom panel and further comprising a smoke detector adjacent to said bottom panel and wherein power to said power cable is terminated in the event of detection of smoke by said smoke detector.

15. A power cable management system comprising:

a housing having an opening;

a power cable at least partially enclosed in said housing and extendable through said opening;

a motor which drives a shaft;

a drive pulley mounted to said shaft and receiving said cable;

a clutch assembly operatively engageable with said shaft and transformable between a drive mode and a release mode;

a movable idler pulley operatively connected to said clutch assembly and receiving said power cable, said power cable being looped around said idler pulley;

wherein said drive pulley, clutch assembly and idler pulley are disposed in said housing and said power cable is moved in either an extending or retracting direction and when said clutch assembly is in a drive mode, said drive pulley is driven and said idler pulley is correspondingly displaced to maintain a substantially continuous slack-free portion of said power cable within said housing when said power cable is moved in both the extending and the retracting directions, and when said clutch assembly is in a release mode, said power cable can be pulled for extension.

16. The cable management system of claim 15 wherein said clutch assembly further comprises a pair of members, one member having a receiver defining a plurality of angularly spaced openings and said other member mounting a plurality of angularly spaced pins which are inserted into the openings in the drive mode.

17. The cable management system of claim 16 wherein said pins are spring biased.

18. The cable management system of claim 15 wherein said clutch assembly comprises a pivotal yoke which engages one of said members and is moveable via a motor for axially displacing said one member.

19. The cable management system of claim 15 wherein said idler pulley is mounted on a trolley which moves in said housing to compensate for the extension or retraction of said power cable.

20. The cable management system of claim 19 further comprising a drive wheel which drives a belt secured to said trolley and said drive wheel being driven by said shaft when said clutch assembly is in a drive mode.

21. The cable management system of claim 20 wherein said drive wheel is mounted to said shaft by a one-way clutch bearing.

22. The cable management system of claim 20 wherein said belt is a timing belt with a plurality of teeth and said drive wheel has a surface generally complementary with said teeth.

23. The cable management system of claim 20 further comprising a tensioner to maintain tension on said belt.

24. The cable management system of claim 19 wherein said trolley comprises a plurality of rollers and said idler pulley is rotatable about an axis orthogonal to the rotational axis of said rollers.

25. The cable management system of claim 15 wherein said drive pulley is mounted to said shaft by a one-way clutch bearing.

26. The cable management system of claim 15 wherein said clutch assembly is transformable by means of a motor which is controlled by a controller mounted in said housing.

27. The cable management system of claim 20 wherein said belt mounts a magnet and further comprising a sensor which senses the position of said magnet to thereby determine the position of said power cable.

28. A power cable management system comprising:

an elongated housing having an opening;

a power cable at least partially enclosed in said housing and extendable through said opening;

a motor selectively operable to bi-directionally drive a shaft;

a drive pulley receiving said cable and mounted to said shaft;

a clutch assembly operatively engageable with said shaft and transformable between a drive mode and a release mode;

a longitudinally movable idler pulley spaced along said power cable from said drive pulley and receiving said power cable so that said power cable loops about said idler pulley and disposed in said housing, said idler pulley being operatively connected to said clutch assembly;

wherein said drive pulley, clutch assembly and idler pulley are disposed in said housing and said power cable is moved in either an extending or retracting direction and when said clutch assembly is in a drive mode, said drive pulley is driven and said idler pulley is correspondingly displaced to maintain a substantially continuous slack-free condition of said power cable within said housing when said power cable is moved in the extending and the retracting directions, and said power cable can be pulled for extension.

29. The cable management system of claim 28, wherein said idler pulley is mounted on a trolley which moves longitudinally in said housing to compensate for the extension or retraction of said power cable.

30. The cable management system of claim 28, wherein said housing is mounted in an overhead orientation and said cable can be lowered to a first height and manually further extend from said opening.