Vehicle and charging system for a vehicle

Abstract

Vehicle charging system (12), comprising: a charging socket (16, 24, 52) designed to connect to a plug (26, 54) of an external power source (28) to recharge a battery (14); a locking mechanism (30, 56, 70) designed to secure the plug (26, 54) to the charging socket (24, 52) when in a locked state; an actuator (78) designed to toggle the locking mechanism (30, 56) between the locked state and an unlocked state when activated, and to maintain the locked or unlocked state when deactivated;and a mechanical override (20) designed to unlock the locking mechanism (30, 56, 70), characterized by an access flap (90) that conceals the mechanical locking override (20) when in a closed position, and allows access to the mechanical locking override (20) when in an open position, and a control (18) designed to terminate a battery recharging operation in response to the opening of the access flap (90).

Description

TECHNICAL AREA The present disclosure relates to charging systems for electric or hybrid vehicles. BACKGROUND Battery electric vehicles (BEVs) and plug-in hybrid vehicles (PHEVs) often have systems that attach the plug of an external power source to the vehicle's charging port during battery recharging. For example, DE 10 2012 013 998 A1 discloses a locking device for a charging plug that can be inserted into a charging socket located on a vehicle or charging station. Patent applications DE 10 2011 115 039 A1 and DE 10 2010 040 522 A1 relate to further exemplary locking devices for a charging cable of an electric vehicle. SUMMARY A vehicle charging system according to claim 1 is provided. The vehicle charging system comprises a charging socket configured to connect to a plug of an external power source for recharging a battery, a locking mechanism for securing the plug to the charging socket when in a locked state, an actuator configured to toggle the locking mechanism between a locked state and an unlocked state when activated, and to maintain the locked or unlocked state when deactivated, and a mechanical override for unlocking the locking mechanism. An access hatch is arranged to conceal the mechanical override when closed and to allow access to the mechanical override when open, and a controller is programmed to terminate a traction battery recharging process in response to a signal indicating that the access hatch is open. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a schematic representation illustrating a vehicle charging system; Fig. 2A is a front view of a first embodiment of a charging socket for a BEV or PHEV; Fig. 2B is an isometric view of a locking device attached to the charging socket of Fig. 2A; Fig. 3 is a side view illustrating a first embodiment of a plug from an external power source and the coupling between the plug and the charging socket of Fig. 2A; Fig. 4A is a front view of a second embodiment of the charging socket for a BEV or PHEV; Fig. 4B is an isometric view of a locking device attached to the charging socket of Fig. 4A; Fig. 5 is a side view illustrating a second embodiment of a plug from an external power source and the coupling between the plug and the charging socket of Fig. 4A; Fig. 6 is an expanded view of a locking device; Fig.Figure 7 is a schematic representation illustrating the mechanical connection between a locking device and a mechanical locking override; and Figures 8A to 8D illustrate the mechanical locking override and an access flap for the mechanical locking override in open and closed positions. DETAILED DESCRIPTION This document describes embodiments of the present disclosure. It is understood, however, that the disclosed embodiments are merely examples and that other embodiments may take different and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to illustrate details of certain components. The specific structural and functional details disclosed herein should therefore not be interpreted as limiting, but merely as a representative basis for teaching a person skilled in the art how the present invention may be carried out in various ways.As can be seen by the average person skilled in the art, various features illustrated and described with reference to any one of the figures can be combined with features illustrated in one or more other figures to form embodiments not expressly illustrated or described. The combinations of illustrated features provide representative embodiments for typical applications. However, for certain applications or implementations, different combinations and modifications of the features may be desired in accordance with the teachings of this disclosure. With reference to Fig. 1, a vehicle 10 is illustrated. The vehicle 10 can be a BEV or a PHEV. The vehicle 10 includes a charging system 12. The charging system 12 is designed to enable the recharging of a vehicle battery 14. The vehicle battery 14 can be a traction battery that provides electrical power to a motor. The motor can provide motive power for the vehicle's transmission and wheels. The electric motor can also function as a generator to recharge the battery 14, in which case it would be referred to as a motor / generator. The motor / generator can be used to recharge the battery 14 under various circumstances.For example, the motor / generator can recharge the battery 14 during regenerative braking, by recovering drive energy during downhill driving when a power machine connected to the motor / generator rotates the motor / generator, or any other method known in the field in which a motor / generator is used to recharge a battery 14 in an electric or hybrid vehicle. The charging system 12 also includes a charging socket 16, which is designed to be connected to the plug of an external power source to recharge the battery 14. The charging system 12 can also include a controller 18, such as an on-board charging device of the vehicle, which is connected to and communicates with both the battery 14 and the charging socket 16. The controller 18 is designed to monitor and control various functions of the charging system 12. For example, the controller 18 can be used to initiate, regulate, and terminate the charging of the battery depending on various factors. These factors may include the current state of charge of the battery, the charging power of the battery, factors related to the protection of the components and / or circuits of the charging system 12 (e.g., overvoltage protection), or safety factors (e.g.,correct connection between the charging socket 16 and the plug of the external power source) include, but are not limited to, The charging socket 16 may include a locking device (or latch) used to secure a plug from an external power source to the charging socket 16 during a battery recharging process. The locking device may also be connected to or in communication with the controller 18. The locking device may include an electric actuator for switching the locking device between locked and unlocked states when activated, and maintaining the locked or unlocked state when deactivated. A mechanical locking override 20 (also referred to as a "mechanical override" or "release") may be connected to the locking device and configured to mechanically override the electric actuator to switch the locking device to the unlocked state.The mechanical locking override 20 may be necessary to disconnect the external power source connector from the charging socket 16 if the electric actuator has failed and the locking device is in the locked position. The mechanical locking override 20 may be sufficiently spaced from the charging socket 16 to provide a safe distance from a charging connection if a user attempts to manually override the locking device to disconnect the external power source connector from the charging socket 16. The mechanical locking override 20 can include an access panel. A sensor 22 can be configured to determine whether the access panel is in an open or closed state. The sensor 22 can also be connected to and communicating with the controller 18. The controller 18 can be programmed to terminate a battery recharging process upon receiving a signal indicating that the access panel is in an open position. The locking device and the mechanical locking override 20 are discussed in more detail below. Although illustrated as a single controller, the controller 18 can be part of a larger control system and be controlled by various other controllers throughout the vehicle 10, such as a vehicle system controller (VSC). It is therefore self-evident that the controller 18 and one or more other controllers together can be referred to as a "controller" that manages various functions of the vehicle 10 and / or the actuators in response to signals from various sensors. The controller 18 may include a microprocessor or a central processing unit (CPU) communicating with various types of computer-readable storage devices or media. Computer-readable storage devices or media may include, for example, volatile or non-volatile memory in read-only memory (ROM), random-access memory (RAM), or other types of memory.These include random-access memory and keep-alive memory (KAM). A KAM is a persistent or non-volatile memory that can be used to store various operating variables while the CPU is disabled. Computer-readable memory devices or media can be implemented using a number of well-known memory devices, such as programmable read-only memory (PROMs), electrically programmable PROMs (EPROMs), electrically erasable PROMs (EEPROMs), flash memory, or any other electrical, magnetic, optical, or combined memory devices capable of storing data, some of which represents executable instructions and which are used by the controller to operate the vehicle. With reference to Fig. 2A, Fig. 2B, and Fig. 3, first embodiments of a charging socket 24, a plug 26 for an external power source 28, and a locking device 30 are illustrated. The charging socket 24 comprises profile elements and electrical connections designed to mate with corresponding profile elements and electrical connections of the plug 26. The profile of the charging socket 24 includes a first receiving space 32 that engages in at least one matching component 35 on the plug 26, and a ramp section 34 that engages a retaining clip 36 on the plug 26. The retaining clip 36 can be biased into a lowered position 38 and designed to move into a raised position 40 when a user presses a release button 42 on the plug 26. The plug 26 can be inserted into the charging socket 24 while the retaining clip 36 is in the raised position 40. The retaining clip 36 moves behind the ramp section 34 while in the raised position 40. Once the plug 26 is fully inserted into the charging socket 24, the release button 42 can be released to move the retaining clip 36 to the lowered position 38. The tip of the retaining clip 36 falls into a cavity 44 located beyond the ramp section 34 and engages a rear face of the ramp section 34 to secure the plug 26 to the charging socket 24. The plug 26 can be withdrawn from the charging socket 24 while the retaining clip 36 is in the raised position 40. The locking device 30 is connected to the charging socket 24. The locking device 30 switches between an unlocked and a locked state to lock or unlock the plug 26 from the charging socket 24. The locking device 30 includes a locking pin 46. The locking pin 46 is located outside the first receiving space 32 when in a retracted position 48, and is designed to protrude into the first receiving space 32 when in a forward position 50. The locking device 30 may include an electric actuator that, when activated, advances the locking pin 46 between the retracted position 48 and the forward position 50, and maintains the retracted position 48 or the forward position 50 when deactivated.The locking pin 46 is designed to lock the plug 26 to the charging socket 24 when in the advanced position 50, by preventing the retaining clip 36 from moving into the raised position 40 when the tip of the retaining clip 36 protrudes into the cavity 44 and engages the rear of the ramp section 34. When the locking pin 46 is in the retracted position 48, the plug 26 can be freely inserted into and withdrawn from the charging socket 24 by pressing the release button 42 and moving the retaining clip 36 into the raised position 40. With reference to Fig. 4A, Fig. 4B and Fig. 5, second embodiments of a charging socket 52, a plug 54 for an external power source 28 and a locking device 56 are illustrated. The charging socket 52 comprises profile details and electrical connections designed to mate with corresponding profile elements and electrical connections of the plug 54. The profile of the charging socket 52 includes a first receiving space 58 that engages in a mating component 60 on the plug 54. The locking device 56 is connected to the charging socket 52. The locking device 56 switches between an unlocked and a locked state to lock or unlock the plug 54 on the charging socket 52. The locking device 56 includes a locking pin 62. The locking pin 62 is located outside the first receiving space 58 when in a retracted position 64, and is designed to protrude into the first receiving space 58 when in a forward position 66. The locking device 56 may include an electric actuator that, when activated, advances the locking pin 62 between the retracted position 64 and the forward position 66, and maintains the retracted position 64 or the forward position 66 when deactivated.The locking pin 62 is designed to lock the plug 54 to the charging socket 52 by extending into a window 68 located on the mating component 60 of the plug 54 when the locking pin 62 is in the advanced position 66. When the locking pin 62 is in the retracted position 64, the plug 54 can be freely inserted into or withdrawn from the charging socket 52. The locking pin 62 is positioned such that it aligns with a window 68 located on a side section of the mating component 60. However, the locking pin 62 and the window 68 can be relocated to other aligned positions on the mating component 60 (or other mating components) of the connector 54 and the charging socket 52. For example, the window 68 can be located on the top of the mating component 60, while the locking pin 62 is located on the top of the charging socket 52, such that the locking pin 62 is now aligned with the window 68 located on the top of the mating component 60. The external power source 28 can be a power supply network, which may include power generation plants, batteries, generators, or any other external power source capable of recharging a battery. The external power sources can be electrical power sources that include either direct current (DC) or alternating current (AC). The mechanical and electrical connections between the various embodiments of the charging socket, the connector that connects the charging socket to an external power source, and the locking device described herein are to be understood as illustrative and not as limiting. The disclosure is to be interpreted as encompassing all electric vehicle charging sockets, including locking devices and the respective connectors that connect the electric vehicle charging sockets to an external power source. With reference to Fig. 6, an exploded view of a locking device 70 is shown. The description of the locking device 70 can also be applied to the two locking devices 30 and 56 described previously. The locking device 70 comprises a first outer housing 72 and a second outer housing 74. The locking device 70 also comprises a locking pin 76, which is designed to alternate between retracted and advanced positions (the retracted and advanced positions of the locking pin 76 can correspond to locked and unlocked states of the locking device 70). An electric actuator 78 can be used to alternate the locking pin 76 between the retracted and advanced positions when activated and to maintain the retracted or advanced position when deactivated.The electric actuator 78 can consist of an electric solenoid, an electric motor, or any other type of actuator capable of switching the locking pin 76 between the retracted and advanced positions. An electrical connection 80 can be included to supply power to the electric actuator 78 and / or to provide a communication link between the locking device 70 and the control unit 18. The locking device 70 can include a mechanical linkage 82 between the electric actuator 78 and the locking pin 76 (such as a gear set) to switch the locking pin 76 between the retracted and advanced positions. The mechanical linkage can include gears (e.g., pinions, bevel gears, gear segments, racks, etc.), pawls, ratchet wheels, shafts, cams, springs, or other hardware designed to advance and retract the locking pin when the electric actuator 78 is activated and to maintain the retracted or advanced position when the electric actuator 78 is deactivated. The mechanical and electrical connections between the components of the mechanical connection 82, the electrical actuator 78, and the locking pin 76 of the locking device 70 described herein are to be understood as illustrative and not as limiting. This disclosure should be interpreted as encompassing all locking devices that have an actuator. With reference to Fig. 7, the connection between the mechanical lock override 20 and the locking device 70 is illustrated. The mechanical lock override 20 can include a handle 84 that is mechanically connected to the locking device 70 such that when a user pulls the handle 84, the locking pin 76 moves from the advanced position to the retracted position (whereby the locking device 70 also moves from a locked state to an unlocked state). The mechanical connection can include a pull cable 86, such as a Bowden cable, that connects the handle 84 of the mechanical lock override 20 to a release mechanism 88 located on the locking device 70.The release mechanism 88 can be a lever, sliding mechanism, or any other device that allows the locking pin 76 to move from the advanced position to the retracted position. For example, the release mechanism 88 can be connected to a pawl, cam, or other component used to lock the mechanical connection 82 located between the electric actuator 78 and the locking pin 76, while simultaneously the locking pin 76 is connected to a preload element, such as a spring, that biases the locking pin 76 in the retracted position. Activation of the release mechanism 88 can release the component that locks the mechanical connection 82 and allow the preload element to retract the locking pin 76. The mechanical connections between the mechanical lock override 20 and the locking device 70 described herein are to be understood as illustrative and not as limiting. This disclosure should be interpreted as encompassing all systems comprising a locking device, an actuator for switching the locking device between locked and unlocked states, and a mechanical lock override configured to override the actuator in order to switch the locking device from a locked state to an unlocked state. With reference to Figures 8A, 8B, 8C, and 8D, the mechanical override 20 is illustrated in more detail. An access panel 90 is arranged to conceal the mechanical locking override 20 when in a closed position and to allow access to the mechanical locking override 20 when in an open position. The sensor 22 is designed to determine whether the access panel 90 is in an open or closed position. The controller 18 can communicate with the sensor 22 and be designed to terminate a battery recharge in response to a signal from the sensor 22 indicating that the access panel is in the open position. The sensor 22 can consist of a limit switch, a microswitch, a proximity switch, or any other device capable of determining whether the access panel 90 is in an open or closed position. Fig. 8A is a front view of the mechanical locking override 20 with the access flap 90 in the closed position, which conceals the mechanical locking override 20. An intuitive logo 92 is affixed to the front of the access flap 90 to help a user recognize the function of the mechanical locking override 20. Fig. 8B is a side view of the mechanical locking override 20 with the access flap 90 in the closed position. The sensor 22 is shown communicating with the controller 18. In this arrangement, the sensor 22 should determine that the access flap 90 is in the closed position. The controller 18 should not terminate a battery recharging process because the access flap 90 is in the closed position. Fig. 8C is a front view of the mechanical lock override 20 with the access flap 90 in the open position. The handle 84 of the mechanical lock override 20 is exposed and accessible to a user when the access flap 90 is in the open position. Fig. 8D is a side view of the mechanical locking override with the access flap in the open position. The sensor 22 is shown communicating with the controller 18. In this arrangement, the sensor 22 should determine the open position of the access flap 90 and send a signal to the controller 18 indicating this open position. The controller 18 should then initiate a battery recharging process based on the signal received from the sensor 22 indicating that the access flap 90 is in the open position. The terms used in the specification are descriptive rather than restrictive, and it is understood that various modifications can be made without altering the essence and scope of the disclosure. As already mentioned, the features of different embodiments can be combined to form further embodiments of the invention, which may not be expressly described or illustrated.It is apparent to those skilled in the art that, although various embodiments could have been described as offering advantages or being preferred over other embodiments or implementations of the prior art with respect to one or more desired characteristics, one or more features or characteristics may be omitted to achieve desired overall system properties, which depend on the specific application and implementation. These properties may include, but are not limited to, cost, strength, durability, life-cycle costs, marketability, appearance, packaging, size, usability, weight, manufacturability, ease of assembly, etc.Accordingly, embodiments that have been described as less desirable than other embodiments or implementations of the prior art with respect to one or more characteristics are not outside the scope of protection of the disclosure and may be desirable for certain applications. It is further described: A. Vehicle charging system, comprising: a charging socket designed to couple with a plug from an external power source to recharge a battery; a locking mechanism designed to secure the plug to the charging socket when in a locked state; an actuator designed to toggle the locking mechanism between the locked state and an unlocked state when activated, and to maintain the locked or unlocked state when deactivated; and a mechanical override designed to unlock the locking mechanism. B. Vehicle charging system according to A, wherein the actuator is an electric solenoid designed to advance a locking pin between an advanced position and a retracted position. C. Vehicle charging system according to A, wherein the actuator is an electric motor designed tothat it advances a locking pin between a forward position and a retracted position. D. Vehicle charging system according to A, wherein the mechanical override further comprises a handle, and the lock is designed to change from the locked state to the unlocked state when a user pulls the handle. E. Vehicle charging system according to D, further comprising a pull cable that mechanically connects the handle to the lock. F. Vehicle, comprising: a charging socket designed to couple with a plug from an external power source to recharge a battery; a lock designed to secure the plug to the charging socket; an electric actuator designed to change the lock between a locked state and an unlocked state when activated, and to maintain the locked or unlocked state.when deactivated; and a mechanical lock override designed to change the lock to the unlocked state. G. Vehicle according to F, wherein the actuator is an electric solenoid designed to advance a locking pin between an advanced position and a retracted position. H. Vehicle according to F, wherein the actuator is an electric motor designed to advance a locking pin between an advanced position and a retracted position. I. Vehicle according to F, wherein the mechanical lock override is spaced apart from the charging socket. J. Vehicle according to F, further comprising an access flap arranged to conceal the mechanical lock override when closed and to provide access to the mechanical lock override when open. K. Vehicle according to J,wherein the mechanical override further comprises a handle, and wherein the lock is designed to be unlocked when a user pulls the handle. L. Vehicle according to K, further comprising a pull cable mechanically connecting the handle to the lock. M. Vehicle according to J, further comprising a controller programmed to terminate a battery recharging operation in response to a signal indicating that the access hatch is open. N. Electric vehicle, comprising: a charging socket designed to be coupled to a plug from an external power source to recharge a traction battery; a lock designed to secure the plug to the charging socket when in a locked state; an electric actuator designed to toggle the lock between the locked and unlocked states when activated.and maintains the locked or unlocked state when deactivated; a release designed to mechanically override the electric actuator to change the lock from the locked to the unlocked state; an access panel arranged to conceal the mechanical release when closed and to provide access to the mechanical release when open; and a controller programmed to terminate a traction battery recharge in response to a signal indicating that the access panel is open. O. Vehicle according to N, wherein the release further comprises a handle, and wherein the lock is designed to change from the locked to the unlocked state when a user pulls the handle. P. Vehicle according to O, further comprising a pull cable mechanically connecting the handle to the lock.

Claims

Vehicle charging system (12), comprising: a charging socket (16, 24, 52) designed to connect to a plug (26, 54) of an external power source (28) to recharge a battery (14); a locking mechanism (30, 56, 70) designed to secure the plug (26, 54) to the charging socket (24, 52) when in a locked state; an actuator (78) designed to toggle the locking mechanism (30, 56) between the locked state and an unlocked state when activated, and to maintain the locked or unlocked state when deactivated;and a mechanical override (20) designed to unlock the locking mechanism (30, 56, 70), characterized by an access flap (90) that conceals the mechanical locking override (20) when in a closed position, and allows access to the mechanical locking override (20) when in an open position, and a control (18) designed to terminate a battery recharging operation in response to the opening of the access flap (90). Vehicle charging system (12) according to claim 1, wherein the actuator (78) is an electric solenoid designed to advance a locking pin (46, 62, 76) between a forward position (50, 66) and a retracted position (48, 64). Vehicle charging system (12) according to claim 1, wherein the actuator (78) is an electric motor designed to advance a locking pin (46, 62, 76) between a forward position (50, 66) and a retracted position (48, 64). Vehicle charging system (12) according to claim 1, wherein the mechanical override (20) further comprises a handle (84), and the locking mechanism (30, 56, 70) is designed to change from the locked state to the unlocked state when a user pulls on the handle (84). Vehicle loading system (12) according to claim 4, further comprising a pull rope (86) which mechanically connects the handle (84) to the locking mechanism (30, 56, 70).

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