Charging device and charging method with floating charging unit

Abstract

Charging device comprising a vehicle with a charging module (2) in the vehicle underbody and a stationary charging station (4) with a charging unit (6) for inductively charging a battery of the vehicle, characterized in that - that the charging station is located close to or in the ground, - that the charging unit is mounted in a floating manner in the charging station, - that the loading unit has a predefined horizontal movement area, - that the charging module has at least one localization magnet (7), - that the charging unit has at least one positioning magnet (8), - that the charging unit is designed as a primary coil, - that the charging module is designed as a secondary coil.

Description

[0001] The invention relates to a charging device and a charging method with a floating charging unit, wherein the charging device comprises a vehicle with a charging module in the vehicle underbody and a stationary charging station with a charging unit for inductively charging a battery of the vehicle.

[0002] In the next decade, electrically powered vehicles, such as electric and hybrid vehicles, will increasingly gain market share in the automotive sector. These vehicles often have an external charging option, usually via a cable. Therefore, such vehicles are also referred to as plug-in hybrids. To achieve widespread mass production, the charging of a plug-in hybrid must be based on a robust, sustainable, and practical concept. The goal is to enable efficient and convenient charging within the framework of public infrastructure (roads and highways) and private infrastructure (parking spaces and garages). Current developments have primarily focused on wired charging stations.

[0003] Wireless charging stations with contactless energy transfer are increasingly being considered. This inductive charging technology is already known in the prior art. For example, German patent DE 42 36 286 A1 describes a device with a secondary charging coil on the vehicle and a primary charging coil on the charging station, which is guided to the vehicle on a guide arm for charging. Since the guide arm is moved by a motor controlled by sensors to establish an optimal charging connection between the two coils, this is a complex and costly design. German patent DE 10 2009 023 409 A1, for example, describes a vehicle docking system in which the vehicle's movement is used to bring a secondary charging coil on the vehicle into contact with a primary charging coil on a charging station. This requires the driver to position the vehicle precisely, i.e.,It may require shunting to move the animal to a precisely specified target position.

[0004] It is an object of the invention to provide an improved charging device and an improved charging method.

[0005] This problem is solved by a charging device and charging method with a floating charging unit according to claim 1. Advantageous embodiments and further developments of the invention are set out in the dependent claims.

[0006] According to the invention, the charging station is mounted near or in the ground. Furthermore, the charging unit is mounted to float within the charging station and has a predetermined horizontal range of motion. The charging module also has at least one locating magnet, and the charging unit has at least one positioning magnet. The charging unit is designed as a primary coil, and the charging module as a secondary coil.

[0007] This means that while the charging station itself can be mounted in a fixed position, the charging unit supporting the primary coil is movably mounted in the horizontal direction, i.e., in the x-direction (longitudinal axis) and y-direction (transverse axis) of a vehicle-related coordinate system, and is therefore not bound to a fixed position within its horizontal range of motion. The term "ground" refers specifically to the plane and the area below it on which the vehicle's wheels roll. For the purposes of this document, "subsurface" is used synonymously.

[0008] According to a preferred embodiment of the present invention, the charging station is at least partially filled with a viscous, non-conductive, and non-magnetic medium with a first density. The charging unit comprises floats and / or hollow bodies with a second density that is lower than the first density.

[0009] The floats or hollow bodies ensure that the loading unit essentially floats on the liquid medium. The necessary buoyancy force of the loading unit results from its partial immersion in the liquid medium.

[0010] Preferably, the at least one localizing magnet, in particular each one, and the at least one positioning magnet, in particular each one, are configured as DC field magnets. Due to the arrangement of the at least one localizing magnet and the at least one positioning magnet, the magnetic field orientation of the at least one localizing magnet and the magnetic field orientation of the at least one positioning magnet result in an attractive positioning force between the at least one localizing magnet and the at least one positioning magnet. This positioning force induces a horizontal movement of the charging unit. In a position of the charging unit designated as the charging position, the potential energy of the positioning magnets in the magnetic field of the localizing magnets is locally minimal with respect to the horizontal range of motion.

[0011] In other words, this means that the positioning magnets are attracted to the locating magnets. When the charging module is within range of the charging station, the charging unit with its primary coil and positioning magnets is attracted to the charging module with its secondary coil and locating magnets. In this case, the charging unit reaches a local minimum of potential energy within its horizontal range of motion, with the location of this minimum being determined by the position of the charging module. If the charging module is not within the horizontal range of motion, the magnetic fields of the locating and positioning magnets can interact, but the charging unit cannot reach this local minimum of potential energy.The loading module is therefore located within the area of ​​horizontal movement if, in the vehicle-fixed coordinate system, its position coordinates with respect to the x-axis and y-axis are the same as those occupied by the moving loading unit in the same reference system. In other words, within this coordinate system, the loading module is located within the horizontal movement range of the loading unit with respect to the x-axis and y-axis.

[0012] If the localization and positioning magnets are electromagnets, according to a special embodiment the magnets can only be energized if the charging module moves in this horizontal coordinate range.

[0013] According to another embodiment, the charging station is integrated into the road surface or the parking space substructure.

[0014] This allows for discreet and space-saving placement of the charging station, for example in public parking lots or in a private garage.

[0015] Preferably, the charging device has a return spring between the charging station and the charging unit. The return spring exerts a spring force on the charging unit in the direction of the center of the horizontal movement area. If the charging module is located within the horizontal movement range of the charging unit, the spring force is less than the positioning force.

[0016] This ensures that the return spring positions the charging unit in the horizontal center of the movement area if no vehicle with a charging module is present at the charging station. This position serves as the starting position of the charging unit if a charging module from a vehicle to be charged is moved into the charging station area.

[0017] The described charging device enables a charging process in which the vehicle first assumes a holding position, during which the charging module is within its range of motion. In this holding position, the floating charging unit is attracted to the charging module, thus reaching the charging position. A battery charging process is initiated upon reaching either the holding or the charging position. This means that the primary coil is powered by an external AC power supply to generate an alternating magnetic field. The inductive energy transfer between the primary and secondary coils is locally maximal in the charging position relative to the horizontal range of motion.

[0018] This charging method offers the driver the advantage that the vehicle is positioned precisely above the charging station for battery charging, provided the charging module is within the horizontal range of motion of the charging unit. The floating charging unit is then automatically moved into the charging position and held there for charging. In the charging position, the energy transfer between the primary and secondary coils is at its maximum. In other words, if the charging unit is located at a point other than the charging position in the x- and / or y-direction, the energy transfer between the coils is lower than in the charging position. The charging position thus represents a local maximum of transferable electrical power.

[0019] According to a further embodiment of the invention, information can be exchanged between the charging station and the charging module. The exchangeable information includes the vehicle's location, battery status information, and control parameters for the battery charging process.

[0020] The information can be used, for example, to assist the driver in assuming a stopping position by providing navigation instructions. Communication between the vehicle and the charging station can also be used to identify the vehicle, for example, to automatically bill the owner for the charging process. By identifying a specific vehicle key, such billing can also be driver-specific.

[0021] After a specific training course, the charging station is movable in a vertical direction relative to the vehicle underbody.

[0022] This allows the charging unit to minimize the spatial distance between the two coils in the vertical direction, i.e. in the direction of the vehicle's vertical axis, once the charging position has been reached, in order to increase the energy transfer from the primary to the secondary coil.

[0023] The invention is based on the considerations set out below: Wired charging stations for electric vehicles or plug-in hybrids are inconvenient and difficult to implement in public infrastructure. Wireless, inductive charging methods currently lack adequate concepts for efficient energy transfer and vehicle coupling. Both of these factors necessitate a close connection between the charging station (i.e., the primary transmission point) and the vehicle to minimize line losses. Furthermore, due to its integration into public infrastructure such as road surfaces or underground parking garage floors, the system must be weather-resistant and compensate for certain inaccuracies or variations in the vehicle's position to minimize charging losses, thus ensuring ideal contact between the charging station and the vehicle "automatically."

[0024] As an improvement measure, a weatherproof charging station will be introduced, containing a charging unit hermetically sealed from the environment. This will utilize a weatherproof, potted housing, for example made of PE or PTFE, which fully integrates the charging unit. The charging station can be integrated into both public infrastructure (e.g., road surface) and private infrastructure (e.g., garage).

[0025] In addition, the weatherproof, integrated charging station features a "self-optimizing" positioning of the charging unit relative to the vehicle to minimize charging losses and allow any position of the charging vehicle.

[0026] A preferred embodiment of the invention is described below with reference to the accompanying drawings. Further details, preferred embodiments, and further developments of the invention will be derived from these drawings. Specifically, the drawings schematically illustrate... Fig. 1 A loading device with a floating unit, view towards the vehicle's longitudinal axis Fig. 2 A loading device with a floating unit, view towards the vehicle's vertical axis (from above)

[0027] The same reference symbols denote the same technical object.

[0028] Fig. 1 and Fig. Figure 2 schematically shows a front or rear section (1) of an electric or hybrid vehicle. A charging module (2) is located on the vehicle's underbody. The charging module, which in particular comprises a secondary coil for inductively charging the vehicle from an external primary coil, has a specific, vehicle-fixed mounting position. When the vehicle is stationary or parked, the charging module defines the origin of the x-axis (longitudinal axis) and the origin of the y-axis (transverse axis) in the vehicle-related coordinate system known to a person skilled in the art.

[0029] The charging module also includes at least one DC field magnet (7), which is referred to as a localization magnet. Without loss of generality, we will further assume that there are two localization magnets. These can be permanent magnets or electromagnets.

[0030] The stationary, inductive charging station (4) is integrated into the ground of the vehicle's parking space (3). The parking space can be, for example, a public charging station in parking lots, rest areas, lay-bys, etc., or a charging station installed in a private area, e.g., in a home garage. The charging station is fixed to the ground and, if its height in the z-direction (vehicle vertical axis) exceeds the ground clearance of common electric and hybrid vehicles, is at least partially embedded in the load-bearing or surface layers and / or the foundation of the road surface or the parking space.

[0031] The charging station essentially consists of a container filled with a liquid medium (5). This medium can be, for example, a viscous, non-magnetic, and electrically non-conductive oil. The charging unit (6) of the inductive charging station is floating within the container and on the liquid medium, meaning it is movably mounted in the x and y directions. The freedom of movement is limited by the container in the x and y directions and is referred to as the horizontal movement area (6a). Ideally, the charging station has a length of 30%–80% of the vehicle width along its transverse axis. Smaller charging stations are also conceivable; however, this restricts the mobility of the charging unit and requires more precise positioning of the vehicle for charging. Particularly in the case of stations that are completely recessed into the ground, the width of the station can even exceed the vehicle width.The charging unit is equipped with the primary coil for inductive power transfer technology known to those skilled in the art. The floating bearing can be achieved by cavities (9) integrated into the primary coil or by floating and / or air bodies housed within the unit, such that the density of the liquid medium exceeds the density of the charging unit. The charging station is powered by alternating current, preferably via the public or domestic AC power grid (11).

[0032] Furthermore, the charging unit has at least one DC field magnet (8), which is designed as a permanent or electromagnet and is referred to as a positioning magnet. Without loss of generality, it is further assumed that there are two positioning magnets.

[0033] To charge the electric or hybrid vehicle, the vehicle is positioned in the parking space with the charging station so that the area of ​​the vehicle with the charging module is located above the charging station's container in the z-direction. Such a parking position is shown schematically in the top view in Fig. Figure 2 illustrates this process. The vehicle user can be assisted by structural positioning aids such as markings, wheel stops, or lateral guide rails in the floor surface. The driver can also be guided electronically, for example by the navigation system, or by acoustic or visual signals, such as those used by parking assistance systems. Data communication between the vehicle and the charging station can also be used for position determination. In any case, to initiate a battery charging process, the driver only needs to position the vehicle roughly relative to the charging station, a position determined by the horizontal movement area. Establishing the vehicle's holding position requires no maneuvering and does not result in any loss of comfort for the driver.When a stationary position is assumed, the position of the loading module with respect to the x-axis and the y-axis may deviate from the position of the loading unit with respect to the x-axis and the y-axis in the same vehicle-fixed coordinate system. However, in the stationary position, the (x,y) position coordinates of the loading module lie within the (x,y) coordinate range that is formed in the same reference system by the horizontal movement surface of the loading unit, see [reference]. Fig. 2.

[0034] The field strengths of the localization and positioning magnets and the viscosity of the liquid medium are designed such that, provided the vehicle assumes a holding position as described above, the magnetic fields of the localization magnets interact with the magnetic fields of the positioning magnets in such a way that the alignment of the magnetic fields results in an attractive force. This force causes the charging unit to move to the position with the minimum potential energy of the positioning magnets relative to the localization magnets. This position is called the charging position. To reach this position, a combined movement in the x- and y-directions, as well as a rotation of the charging unit around the z-axis, may occur.

[0035] High energy transfer with minimal energy loss occurs when the magnetic flux through the secondary coil of the primary coil is as high as possible. With respect to the x- and y-directions, this is ensured in the charging position by the position of the locating magnets relative to the secondary coil and the positioning magnets relative to the primary coil. It should be noted that the charging unit can assume the optimal charging position both when charging is activated (i.e., when the primary coil is operating with a high-frequency alternating magnetic field) and when the primary coil is deactivated. With the alternating field activated, this has no effect on the interaction of the static fields of the locating and positioning magnets over time. With respect to the z-axis, the energy transfer is more efficient the smaller the distance between the primary and secondary coils is in the optimal charging position.This distance is determined by the vehicle's ground clearance, the installation depth of the charging station in the ground, and the fill level of the liquid medium in the tank. The distance can be minimized by maximizing the fill level of the liquid medium in the tank in the positive z-direction and by minimizing the distance between the vehicle's underbody and the charging station when the vehicle is stationary. For this purpose, the charging station and / or its integration in the ground can be designed for a specific vehicle type. Alternatively, the vehicle design can also be adapted to the parking space and the charging station.

[0036] According to another embodiment, the charging station or the vehicle can be raised and lowered relative to the charging station in order to minimize the distance between the two coils in the optimal charging position. This can be achieved, for example, with a lifting or lowering platform for the charging station or the vehicle that is also integrated into the parking space.

[0037] During charging, the charging unit remains in the optimal charging position, as this position forms a local energy minimum as described above.

[0038] After a charging process has been completed and / or after the vehicle has been moved from the holding position, the charging unit assumes a predetermined starting position in the container, which is, for example, via an integrated return spring (10) centrally attached to the charging station and charging unit, see Fig.1. The spring force of the restoring force is to be designed to be so low as to match the minimum attractive force of the localization and positioning magnet when the vehicle is in a holding position that the movement of the charging unit is not suppressed.

[0039] In another design of the charging device, a charging process can only be activated once the vehicle has reached a holding position. This can be achieved through a communication link between a communication unit on the vehicle and a communication unit at the charging station, connecting the vehicle to the charging station or even to the grid operator. This link can also be combined with vehicle identification and / or the vehicle's position tracking described above. From this, business models for automated billing of the charging process with the electricity supplier can be derived, provided that the vehicle identification also includes driver or owner identification, for example, via the identification of a specific vehicle key assigned to a natural or legal person.

[0040] The described charging device and charging method offer significant advantages, particularly for the driver. Thanks to its self-optimizing, magnetic field-based design, which eliminates externally moving parts, the charging station can be designed to be very simple and robust. Such a charging station, permanently installed on the ground, promises not only ease of use but also a long service life. For outdoor applications, the charging device is particularly weather-resistant, as all electrical components can be housed within the container or buried underground. This includes, for example, the connection to the external AC power grid and the communication unit. Reference symbol list 1 Front or rear axle 2 charging modules 3 parking space surface 4 charging stations 5 Liquid medium 6 charging units 6a Horizontal movement area 7 Localization magnet 8 Positioning magnet 9 cavities or floats 10 Return spring 11 Alternating current network x Longitudinal axis y transverse axis z vertical axis

Claims

[1] Charging device comprising a vehicle with a charging module (2) in the vehicle underbody and a stationary charging station (4) with a charging unit (6) for inductively charging a battery of the vehicle, characterized by , - that the charging station is located close to or in the ground, - that the charging unit is mounted in a floating manner in the charging station, - that the loading unit has a predefined horizontal movement area, - that the charging module has at least one localization magnet (7), - that the charging unit has at least one positioning magnet (8), - that the charging unit is designed as a primary coil, - that the charging module is designed as a secondary coil. [2] Charging device according to claim 1, characterized by , - that the charging station is at least partially filled with a viscous, non-conductive and non-magnetic medium with a first density, - that the loading unit has floats and / or hollow bodies with a second density, - that the first density is greater than the second density. [3] Charging device according to one of claims 1 or 2, characterized by , - that at least one localization magnet is designed as a DC field magnet, - that at least one positioning magnet is designed as a DC field magnet, - that the at least one localizing magnet and the at least one positioning magnet are arranged such that the magnetic field orientation of the at least one localizing magnet and the magnetic field orientation of the at least one positioning magnet result in an attractive positioning force between the at least one localizing magnet and the at least one positioning magnet, - that a horizontal movement of the loading unit can be effected by the positioning force, - that in a charging position of the charging unit, the potential energy of the positioning magnets in the magnetic field of the locating magnets and in relation to the horizontal range of movement is locally minimal. [4] Charging device according to any one of claims 1 to 3, characterized by , - that the charging station is integrated into the road surface or the parking space substructure. [5] Charging device according to any one of claims 1 to 4, characterized by , - that the charging device has a return spring between the charging station and the charging unit, - that the return spring exerts a spring force on the loading unit in the direction of the center of the horizontal movement surface, - that when the charging module is located in the horizontal range of motion of the charging unit, the spring force is less than the positioning force. [6] Charging device according to any one of claims 1 to 5, characterized by , - that information can be exchanged between the charging station and the charging module, - that the information includes location details of the vehicle, - that the information includes battery status information, - that the information includes control parameters for a battery charging process. [7] Charging device according to one of the preceding claims, characterized by , - that the charging station is movable in a vertical direction relative to the vehicle underbody. [8] Charging method for a charging device according to any one of claims 3 to 6, characterized by , - that the vehicle is moved into a holding position in which the charging module is within range of motion, - that in the holding position the floating charging unit is attracted by the charging module and reaches the charging position, - that a battery charging process is started when the holding position or the charging position is reached, - that the inductive energy transfer between the primary coil and the secondary coil is locally maximal in the charging position with respect to the horizontal range of motion. [9] Charging method with a charging device according to claim 7, characterized by , - that the vehicle is moved into a holding position in which the charging module is within range of motion, - that in the holding position the floating charging unit is attracted by the charging module and reaches the charging position, - that a battery charging process is started when the holding position or the charging position is reached, - that the inductive energy transfer between the primary coil and the secondary coil is locally maximal in the charging position with respect to the horizontal range of motion, and - that the vertical distance between the primary coil and the secondary coil is minimized by moving the charging station in a vertical direction to increase the power transferred.

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