Automatic power connector for recharging electric vehicles

• US 5,272,431 A
• Filed: 11/27/1991
• Issued: 12/21/1993
• Est. Priority Date: 11/27/1991
• Status: Expired due to Fees

• Current Assignee: Patrick W. Nee
• Original Assignee: Patrick W. Nee
• Inventors: Nee, Patrick W.
• Primary Examiner(s): Peckman, Kristine L.
• Application Number:
  US07/800,187
• Time in Patent Office: 755 Days
• Field of Search: 320/2, 320/5, 320/8, 320/56, 307/10.7, 180/65.1, 180/65.2, 180/65.3
• US Class Current: 320/109
• CPC Class Codes: B60L 2210/30 AC to DC converters
• CPC Class Codes: B60L 2250/10 by alarm
• CPC Class Codes: B60L 3/0023 Detecting, eliminating, remedying or compensating for drive train abnormalities, e.g. failures within the drive train
• 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 53/16 Connectors, e.g. plugs or sockets, 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 53/35 Means for automatic or assisted adjustment of the relative position of charging devices and vehicles
• 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: B60L 53/665 Methods related to measuring, billing or payment
• 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 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
• 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
• CPC Class Codes: Y10S 320/12 : Precharging analysis, e.g. determining presence of battery

Abstract

The invention supplies electricity to a recharger used to recharge batteries in a battery-powered vehicle. An arm mechanism is attached to the vehicle and moveable relative to the vehicle. At the distal end of the arm is an electrical plug protected by a retractable sheath and electrically connected to the recharger. A docking station located remote from the vehicle, emitting light and containing a conical passageway for guiding the plug to the outlet. A docker attached to the vehicle, containing optical sensors tuned to the light emitted by the docking station. Software instructions move the arm mechanism to seek the outlet, calculate the position of the outlet, and move the arm mechanism to connect the plug to the outlet. Software instructions activate the electrical supply to the outlet if the vehicle is authorized to receive electricity.

Claims

1. For a vehicle equipped with at least one electrical component, an electrical power coupling system for supplying electricity from a power supply to the vehicle comprising:

a) a first power coupler attached to the vehicle and coupled to the electrical component;

b) an arm mechanism attached to the vehicle and to which the first coupler is attached, the arm mechanism being movable in a multi-dimensional zone of motion relative to the vehicle;

c) a second power coupler remote from the vehicle and coupled to the power supply, the second coupler being located at an arbitrary position within the multi-dimensional zone of motion;

d) an indicator remote from the vehicle for indicating the location of the second coupler with respect to the vehicle; and

e) a locator attached to the vehicle for seeking and locating the second coupler based on the indication from the indicator to enable coupling of the first coupler to the second coupler by translating the arm mechanism within the multi-dimensional zone of motion.

2. The coupling system of claim 1 wherein the indicator comprises a homing beacon for generating signals indicating the location of the second coupler.

3. The coupling system of claim 1 wherein the electrical component comprises a rechargeable battery.

4. The coupling system of claim 3 further comprising a recharger for recharging the battery, the recharger electrically coupled between the battery and the first coupler.

5. The coupling system of claim 1 wherein the first coupler is a plug and the second coupler is an outlet.

6. The coupling system of claim 1 wherein the multi-dimensional zone of motion is defined by a first axis extending longitudinally relative to the vehicle, a second axis extending laterally relative to the vehicle, and a third axis extending normal to the underbody of the vehicle.

7. For a battery-powered vehicle including a rechargeable battery, a charging system for supplying electricity to the vehicle battery comprising:

a) an arm mechanism attached to the vehicle and moveable in a multi-dimensional zone of motion relative to the vehicle, the arm mechanism having a distal end with an electrical plug at the distal end, the plug being electrically coupled to the battery;

b) a docking station located remote from the vehicle within the multi-dimensional zone of motion, the docking station containing an electrical outlet electrically coupled to an electrical power supply and an outlet homing beacon which generates signals indicating the location of the outlet;

c) a docker attached to the vehicle and in electrical communication with the arm mechanism for automatically coupling the plug to the outlet in response to the signals; and

d) a power controller in electrical communication with the docking station for the outlet and the power supply.

8. The charging system of claim 7, wherein the plug is encased within a retractable protective sheath.

9. The charging system of claim 7, wherein angular displacement of the arm mechanism relative to the edge of the vehicle is moveable substantially within 0 to 180 degrees.

10. The charging system of claim 7, wherein the arm mechanism retracts to a secure position while not activated.

11. The charging system of claim 7, wherein the outlet homing beacon comprises an LED, which emits light with a frequency response that is distinguishable from background light.

13. The charging system of claim 7, wherein the docker includes at least one sensor, a processor, a memory, and software instructions residing in the memory and executed by the processor.

15. The charging system of claim 13, wherein the software instructions calculate the approximate position of the outlet, translate the plug to the outlet, detect a connection with the outlet and establish a communication link with the docking station.

16. The charging system of claim 7, wherein the power controller comprises a processor, a memory, and software instructions residing in the memory and executed by the processor.

17. The charging system of claim 16 further comprising an authorizer for establishing a communications link with the docker and determining whether the vehicle is authorized for recharging.

18. The charging system of claim 17 further comprising an activator for connecting and disconnecting the power supply to the outlet.

19. The charging system of claim 18 further comprising an accounter for determining the amount of energy used by the vehicle.

20. The charging system of claim 19 further comprising a meter for measuring power usage by the vehicle during the recharging of the battery.

21. The charging system of claim 7 further comprising a recharger for recharging the battery, the recharger electrically coupled between the battery and the plug.

32. The method of claim 20 further comprising detecting the coupling between the plug and the outlet and establishing a communication link between the vehicle and the docking station.

33. The method of claim 32 further comprising authenticating the vehicle for recharging at the docking station.

34. The method of claim 33 further comprising measuring the energy used by the vehicle.

35. The method of claim 33 wherein the step of authenticating is based on a unique identification code.

36. The method of claim 35 wherein the unique identification code is a Vehicle Identification Number.

12. The charging system 7, wherein the docking station includes a conical passageway for guiding the plug to the outlet.

14. The charging system 13, wherein the at least one docker sensor is tuned to distinguish the outlet homing beacon signals from background signals.

22. For a battery-powered vehicle including a recharger for recharging a rechargeable battery, a charging system for supplying electricity to the recharger comprising:

a) an arm mechanism attached to the vehicle and having a distal end, the arm mechanism being movable relative to the vehicle, the arm mechanism containing an electrical plug electrically coupled to the recharger and encased within a retractable protective sheath at the distal end, and the arm mechanism being retractable to a secure position when not active;

b) a docking station located remote from the vehicle, the docking station containing an electrical outlet electrically coupled to an electrical power supply and wherein the outlet is located at the focus of a substantially conical passageway leading from a face surface of the docking station, the docking station emitting light with a frequency response that is distinguishable from background light for guiding the plug to the outlet;

c) a docker attached to the vehicle and in electrical communication with the arm mechanism, containing at least one optical sensor tuned to the emitted light from the docking station, a first processor, a first memory, and first software instructions residing in the first memory and executed by the first processor, the first software instructions moving the arm mechanism to seek the emitted light, calculating the approximate position of the outlet, translating the arm mechanism to connect the plug to the outlet, and establishing a communication link with the docking station; and

d) a power controller remote from the vehicle and in electrical communication with the docking station containing a second processor, a second memory, and second software instructions residing in the second memory and executed by the second processor, an authorizer for establishing a communication link with the docker and determining whether the vehicle is approved for recharging, an activator controlling the power supplied to the outlet, and a meter and accounter for measuring the energy used by the vehicle for billing purposes.

23. A method of providing electricity to an electrical component in a vehicle by automatically coupling a moveable first power coupler attached to the vehicle by an arm mechanism having a multi-dimensional zone of motion relative to the vehicle to a second power coupler located remote from the vehicle, comprising the steps of:

a) in a docking station where the second coupler is located, generating an indicator signal;

b) positioning the vehicle such that the second coupler is located within the multi-dimensional zone of motion of the arm mechanism; and

c) in the vehicle,

i) sensing the indicator signal generated by the docking station;

ii) locating the approximate position of the second coupler by analyzing the indicator signal; and

iii) translating the arm mechanism within the multi-dimensional zone of motion relative to the vehicle and urging the first coupler to couple with the second coupler.

24. The method of claim 23 wherein the first coupler is a plug and the second coupler is an outlet.

25. The method of claim 23 wherein the step of translating is within a three-dimensional zone of motion relative to the vehicle.

26. A method of recharging a battery-powered vehicle equipped with a rechargeable battery, comprising the steps of:

a) automatically coupling an in-vehicle electrical plug attached to a moveable arm mechanism having a multi-dimensional zone of motion relative to the vehicle to an electrical outlet attached to a remote docking station in response to signals generated by the docking station; and

b) electrically connecting the outlet to a power source.

27. The method of claim 26 further comprising projecting the plug from a protective sheath.

28. The method of claim 26 further comprising directing the vehicle'"'"'s arm mechanism to the outlet in response to a homing beacon.

29. The method of claim 28 wherein the directing step is in response to light waves generated by the docking station.

30. The method of claim 26 further comprising funnelling the plug into the outlet.

31. The method of claim 30 further comprising retracting a protective sheath to expose the plug.

37. For a battery-powered vehicle including a rechargeable battery, a charging system for supplying electricity to the vehicle battery comprising:

a) an arm mechanism attached to the vehicle and moveable relative to the vehicle, the arm mechanism having a distal end with an electrical plug at the distal end, the plug being electrically coupled to the battery and wherein the arm mechanism is retracted to a secure protected position when not activated;

b) a docking station located remote from the vehicle, the docking station containing an electrical outlet electrically coupled to an electrical power supply and an outlet homing beacon which generates signals indicating the location of the outlet;

c) a docker attached to the vehicle and in electrical communication with the arm mechanism for activating the arm mechanism and automatically coupling the plug to the outlet in response to the signals; and

d) a power controller in electrical communication with the docking station for electrically connecting the outlet and the power supply.

38. For a battery-powered vehicle including a rechargeable battery, a charging system for supplying electricity to the vehicle battery comprising:

a) an arm mechanism attached to the vehicle and moveable relative to the vehicle, the arm mechanism having a distal end with an electrical plug at the distal end, the plug being electrically coupled to the battery;

b) a docking station located remote from the vehicle, the docking station containing an electrical outlet electrically coupled to an electrical power supply and an outlet homing beacon which generates signals indicating the location of the outlet;

c) a docker attached to the vehicle and in electrical communication with the arm mechanism for automatically coupling the plug to the outlet in response to the signals, the docker including at least one sensor, a processor, a memory, and software instructions residing in the memory and executed by the processor; and

d) a power controller in electrical communication with the docking station for electrically connecting the outlet and the power supply.

39. The charging system of claim 38, wherein the at least one docker sensor is tuned to distinguish the outlet homing beacon signals from background signals.

40. The charging system of claim 38, wherein the software instructions calculate the approximate position of the outlet, translate the plug to the outlet, detect a coupling between the plug and the outlet, and establish a communication link with the docking station.

41. For a battery-powered vehicle including a rechargeable battery, a charging system for supplying electricity to the vehicle battery comprising:

a) an arm mechanism attached to the vehicle and moveable relative to the vehicle, the arm mechanism having a distal end with an electrical plug at the distal end, the plug being electrically coupled to the battery;

b) a docking station located remote from the vehicle, the docking station containing an electrical outlet electrically coupled to an electrical power supply and an outlet homing beacon which generates signals indicating the location of the outlet;

c) a docker attached to the vehicle and in electrical communication with the arm mechanism for automatically coupling the plug to the outlet in response to the signals; and

d) a power controller in electrical communication with the docking station for electrically connecting the outlet and the power supply, the power controller comprising a processor, a memory, and software instructions residing in the memory and executed by the processor.

42. The charging system of claim 41 further comprising an authorizer for establishing a communications link with the docker and determining whether the vehicle is authorized for recharging.

43. The charging system of claim 42 further comprising an activator for connecting and disconnecting the power supply to the outlet.

44. The charging system of claim 43 further comprising an accounter for determining the amount of energy used by the vehicle.

45. The charging system of claim 44 further comprising a meter for measuring power usage by the vehicle during the recharging of the battery.

46. A method of recharging a battery-powered vehicle equipped with a rechargeable battery, comprising the steps of:

a) automatically seating an in-vehicle electrical plug attached to a moveable arm mechanism to an electrical outlet attached to a remote docking station in response to signals generated by the docking station;

b) directing the arm mechanism to the outlet in response to light waves generated by the docking station;

c) electrically connecting the outlet to a power source.

47. A method of recharging a battery-powered vehicle equipped with a rechargeable battery comprising the steps of:

a) automatically seating an in-vehicle electrical plug attached to a moveable arm mechanism to an electrical outlet attached to a remote docking station in response to signals generated by the docking station;

b) detecting the seating between the plug and the outlet;

c) establishing a communication link between the vehicle and the docking station; and

d) electrically connecting the outlet to a power source.

48. The method of claim 47 further comprising measuring the energy used by the vehicle.

49. The method of claim 47 further comprising the step of authenticating he vehicle for recharging at the docking station, the authenticating step occurring before the electrically connecting step.

50. The method of claim 49 wherein the step of authenticating is based on a unique identification code.

51. The method of claim 50 wherein the unique identification code is a Vehicle Identification Number.