System and method for automatic connector coupling for an electric vehicle

• US 10,843,584 B2
• Filed: 11/06/2018
• Issued: 11/24/2020
• Est. Priority Date: 11/06/2018
• Status: Active Grant

• Current Assignee: ABB BV (ABB Limited)
• Original Assignee: ABB Schweiz AG (ABB Limited)
• Inventors: Cole, Gregory A., Eakins, William J., Krucinski, Martin, Choi, Sangeun, Fuhlbrigge, Thomas A.
• Primary Examiner(s): Tso, Edward
• Assistant Examiner(s): Omar, Ahmed H
• Application Number:
  US16/182,129
• Publication Number:
  US 20200139820A1
• Time in Patent Office: 749 Days
• Field of Search: 320109
• 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 53/35 Means for automatic or assisted adjustment of the relative position of charging devices and vehicles
• CPC Class Codes: H01R 13/447 Shutter or cover plate
• CPC Class Codes: H01R 2201/26 for vehicles
• CPC Class Codes: H01R 43/26 for engaging or disengaging the two parts of a coupling device structural association with two-part coupling device H01R13/629
• CPC Class Codes: H02J 7/0045 concerning the insertion or the connection of the 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 connector arrangement for charging an electric vehicle includes a first connector disposed adjacent a slide surface and having a pin extending from the first connector. A second connector has a second connector body and is moveable along the slide surface by a linkage mechanism. A socket extends through the second connector body between two opposed openings, and at least one sensor is associated with the second connector body. The at least one sensor provides information indicative of a location of the second connector body on the slide surface to the linkage mechanism.

Claims

1. A connector arrangement for charging an electric vehicle, comprising:

a slide surface disposed on the electric vehicle, the slide surface being planar and flat;

a first connector having a first connector body, the first connector body disposed on the electric vehicle adjacent the slide surface;

a second connector having a second connector body, the second connector body being attached to and moveable by a linkage mechanism, wherein the linkage mechanism is configured to move the second connector body into sliding contact with the slide surface;

at least one sensor associated with the second connector body, the at least one sensor providing information indicative of a location of the second connector body on the slide surface to the linkage mechanism; and

a shuttle associated with the electric vehicle;

wherein the linkage guides the second connector body in one direction, and the shuttle guides the second connector body in another direction, along the slide surface, based on information from the at least one sensor, to electrically couple the first and second connector bodies.

2. The connector arrangement of claim 1, wherein the second connector body has a rectangular shape and includes four sensors, each of the four sensors disposed at a corner of the second connector body.

3. The connector arrangement of claim 2, wherein a contact signal from two sensors disposed on one side of the second connector body indicates to the linkage mechanism alignment of the second connector body with an end wall of the slide surface in one direction, and causes the linkage mechanism to move the second connector body along the end wall in the one direction.

4. The connector arrangement of claim 3, wherein a contact signal from three sensors indicates to the linkage mechanism alignment of the second connector body with a corner between two end walls of the slide surface.

5. The connector arrangement of claim 4, wherein the shuttle is a protective door disposed between the one connector and the mating connector, wherein the linkage mechanism is arranged to allow the protective door to open when the second connector body is determined to be in the corner before moving the second connector body into engagement with the first connector body after the contact signal from the three sensors is provided to the linkage mechanism.

6. A method for automatically aligning and engaging two connectors for charging an electric vehicle, comprising:

providing a slide surface on the electric vehicle, the slide surface having a planar, rectangular shape that is delimited by end walls;

providing a first connector at a corner of two end walls of the slide surface;

placing a second connector in sliding contact with the slide surface;

sliding the second connector along the slide surface in one direction until the second connector contacts an end wall;

aligning the second connector with the end wall;

sliding the second connector along the slide surface in another direction along the end wall until the second connector reaches the corner; and

pushing the second connector to mate with the first connector.

7. The method of claim 6, wherein placing the second connector on the slide surface and moving the second connector along the slide surface is accomplished by a linkage mechanism responsive to controller commands.

8. The method of claim 7, further comprising sensing contact of the second connector with the slide surface using sensors associated with the second connector, wherein placing the second connector on the slide surface further includes verifying using signals from the sensors that the second connector is placed flat on the slide surface along four corners of the second connector.

9. The method of claim 8, further comprising using the sensors to determine contact of the second connector with the end wall and the corner.

10. The method of claim 9, wherein the linkage mechanism moves the second connector along the end wall while maintaining contact with the slide surface and based on the signals from the sensors indicating that the second connector slides along the slide surface and the end wall.

11. The method of claim 6, wherein the first connector includes at least one pin, and the second connector forms at least one socket, and wherein when the second connector is placed in the corner, the at least one pin is aligned to enter into the at least one socket.

12. The method of claim 7 wherein the slide surface has a rectangular shape and is disposed on the underside of an electric vehicle, and wherein the linkage is disposed on a floor surface below the electric vehicle.

13. The method of claim 12, wherein the second connector is electrically connected to an electric voltage source, wherein the first connector is electrically connected to a battery of the electric vehicle, and wherein electric potential is transferred from the electric voltage source to charge the battery when the first connector is mated with the second connector.

14. The method of claim 6, wherein the second connector has a rectangular shape with a proximity sensor array placed in each corner laterally and also in contact with the slide surface.

15. The method of claim 14, wherein contact with the end wall is based on signals provided from one of four sensors in a lateral direction.

16. The method of claim 15, wherein alignment with the end wall is based on signals provided from two of the four sensors in the lateral direction.

17. The method of claim 16, wherein alignment with the corner is based on signals provided from three of the four sensors in the lateral direction.

18. The method of claim 17, wherein the first connector is placed in a receptacle that is enclosed on three sides, and wherein a mated position of the first connector with the mating second connector is based on a signal provided by an additional sensor associated with the first connector, which signal indicates that the second connector is fully engaged with the first connector.

19. A method for automatically coupling a charging side connector with a vehicle connector, comprising:

providing a slide surface on an underside of an electric vehicle, the slide surface being generally flat and planar along two directions and being delimited by end walls that meet at corners, wherein the vehicle side connector is disposed at one of the corners;

lifting the charging side connector with a linkage mechanism to meet the slide surface, the linkage mechanism arranged to slide the charging side connector along the slide surface;

sliding the charging side connector along the slide surface in one direction with the linkage until the charging side connector contacts an end wall that terminates at the one corner;

aligning the charging side connector with the end wall;

sliding the charging side connector in another direction along the end wall towards the one corner until the charging side connector reaches the one corner; and

engaging the charging side with the vehicle side connectors.

20. The method of claim 19, further comprising using a shuttle to move the charging side connector towards the one corner, engaging the charging side connector with the shuttle, and pulling the charging side connector with the shuttle to uncouple the charging side connector from the vehicle side connector.