Extendable inductive vehicle charging system

Abstract

Vehicle (102), which includes: an inductive charging plate arrangement which is arranged in a recess of the vehicle (102) and has a pivoting arm (208) which is pivotably attached to a mounting surface, and a loading plate receiver (210) which is pivotably attached to the pivoting arm (208) such that the loading plate receiver (210) changes from an end to a side orientation and moves along an arc (230) defined by a length of the pivoting arm (208) when the arrangement moves between a retracted position inside the recess and an extended position below the recess, characterized by the fact that the lateral orientation of the loading plate receiver (210) is rotated from the end orientation, the loading plate receiver (210) has a flat surface and the flat surface is generally parallel to a horizontal plane of the vehicle (102) when the arrangement is in the extended position, and wherein the loading plate receiver (210) is offset from a median plane (108) of the vehicle (102) when the arrangement is in the retracted position, and the loading plate receiver (210) intersects the median plane (108) when the arrangement is in the extended position.

Description

TECHNICAL FIELD

[0001] This disclosure relates to an inductive vehicle charging system for a traction battery, and more particularly to an inductive vehicle charging plate assembly and construction. BACKGROUND OF THE INVENTION

[0002] Battery electric vehicles (BEVs) and plug-in hybrid electric vehicles (PHEVs) (collectively referred to as EVs or xEVs) can use an electric motor as their primary or sole source of propulsion energy. A BEV or PHEV typically requires an external power source to charge the vehicle-mounted battery that powers the motor.

[0003] The increasing popularity and sales of battery electric vehicles (BEVs) and plug-in hybrid electric vehicles (PHEVs) have contributed to advances in vehicle and charging system technology. Using a charging cable to connect a vehicle to a power grid can be viewed as inconvenient by potential BEV and PHEV owners. One way to enable charging without physically connecting the vehicle to a power grid is to use a wireless inductive charging system. Such wireless inductive charging systems are commonly used in electronic devices such as electric toothbrushes and mobile phones. Now, wireless inductive charging systems are being proposed for charging BEVs and PHEVs.US Pat. No. 5,595,271 A describes a vehicle comprising an inductive charging plate assembly having a pivoting arm pivotally mounted to a mounting surface and a charging plate receiver pivotally mounted to the pivoting arm such that the charging plate receiver is positioned within a recess defined by an underbody of the vehicle when the assembly is retracted and travels along a floor defined by a length of the pivoting arm when the assembly moves between the retracted and extended positions, the charging plate receiver having a flat surface, the flat surface being generally parallel to a horizontal plane of the vehicle when the assembly is in the extended position. Further prior art relating to the background of the invention is provided by JP 2011-193617A.

[0004] Wireless inductive charging uses an electromagnetic field to transfer energy from a transmitting coil on the ground to a receiving coil mounted on the vehicle. The receiving coil required to charge a vehicle is much larger than the one needed to charge a cell phone or a toothbrush. Larger coils can transfer more energy than smaller ones. For example, it is often difficult to find enough space to accommodate a large receiving coil under a vehicle.

[0005] The proximity of the two coils influences the efficiency of energy transfer. For example, it is desirable to position the receiving coil along the center of the vehicle, allowing the operator to more easily park the vehicle over the transmitting coil. Placing the receiving coil in the center of the vehicle also protects the operator and passersby from the electromagnetic field generated by these large inductive charging coils. This further limits the options for easily accommodating the transmitting coil on the underside of a vehicle. SUMMARY

[0006] A vehicle includes an inductive charging pad assembly. The assembly includes a pivot arm pivotally mounted to a mounting surface and a charging pad receiver pivotally mounted to the pivot arm such that the charging pad receiver transitions from an end-to-side orientation and travels along an arc defined by a length of the pivot arm as the assembly moves between the retracted and extended positions.

[0007] A vehicle includes an inductive charging pad assembly. The assembly includes a pivoting arm pivotally mounted to a mounting surface and a charging pad receiver pivotally mounted to the pivoting arm such that the charging pad receiver is disposed within a recess defined by an underbody of the vehicle when the assembly is retracted and travels along an arc defined by a length of the pivoting arm when the assembly moves between the retracted and extended positions.

[0008] An inductive charging plate assembly includes a charging plate receiver having a flat main surface and is mechanically coupled to a pivoting arm such that the charging plate receiver pivots relative to the pivoting arm when the pivoting arm rotates between a retracted and extended position, and the flat main surface achieves a perpendicular orientation relative to the ground when the assembly is in a vehicle and in the retracted position. BRIEF DESCRIPTION OF THE DRAWINGS Fig. is an example side view showing positions of an inductive charging plate on a vehicle. Fig. is an example rear view showing positions of an inductive charging plate on a vehicle. Fig. is an exemplary rear view illustration of an inductive charging plate receiver assembly in an extended and a retracted position. Fig. is an exemplary side view illustration of an inductive charging plate receiver assembly in an extended and a retracted position. Fig. is an exemplary side view illustration of an alternative inductive charging plate receiver assembly in an extended and a retracted position. DETAILED DESCRIPTION

[0009] Embodiments of the present disclosure are described herein. However, it is to be understood that the disclosed embodiments are intended only as examples, and that other embodiments may take various and alternative forms. The drawings are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for providing one skilled in the art to variously employ the present invention.Those skilled in the art will understand that various features illustrated and described herein with reference to any of the figures may be combined with features illustrated in one or more other figures to produce embodiments that are neither explicitly illustrated nor described. The combinations of illustrated features provide representative embodiments for typical applications. However, various combinations and modifications of the features consistent with the teachings of this disclosure may be desired for particular applications or implementations.

[0010] Typically, the goal of a vehicle manufacturer is to reduce the weight of a vehicle, as weight is directly related to the vehicle's fuel economy. Another aspect of importance for vehicle manufacturers is to reduce the cost and complexity of the vehicle while meeting customer preferences and requirements. To reduce weight, cost, and complexity, many inductive charging systems for xEVs are designed with a stationary charge plate receiver on the vehicle, and a charge plate transmitter at the charging station that is movable to align the charge plate receiver and transmitter. The charge plate transmitter can be moved close to the charge plate receiver during a charging cycle to improve energy transfer. This design enables low weight, low cost, and robust mounting for the charge plate receiver on the vehicle.

[0011] Disclosed herein is an alternative inductive charging plate assembly in which a charging plate receiver is coupled to the vehicle via a mechanism including a pivoting arm. The pivoting arm may be configured as a robust mechanism that allows rapid movement of the charging plate receiver from a stowed position to an extended position. The extended position is a position in which the charging plate is ready for use, and the stowed position is used to store, protect, and secure the charging plate receiver when the vehicle is not charging and when the vehicle is moving.

[0012] In one embodiment, the load plate receiver is operational when the load plate receiver extends away from the underbody of the vehicle so that it can be aligned flush or substantially flush with the ground surface beneath the vehicle near a load plate transmitter. In the extended position, the load plate receiver can be held substantially level with the horizon or a horizontal plane on which the vehicle is resting. This embodiment also includes a stowed position, also referred to as a retracted position, which includes a position in which the load plate receiver is retracted close to the body of the vehicle or retracted into the recess of the vehicle such that a vehicle ground clearance between components on the underside of the vehicle and the horizontal plane on which the vehicle is resting is greater than a predetermined distance.The orientation of the platform receiver may change between the stowed and deployed positions, or may remain substantially the same. For example, in one embodiment, a platform receiver may be in a horizontal position when deployed and rotated to a vertical position when stowed. Underbody recesses and cavities may be used for stowing in a vertical position. In an alternative embodiment, the platform receiver may remain horizontal in both the deployed and stowed positions.

[0013] Another advantage of using a pivoting arm can be that the charging plate receiver position can be offset from the position of the charging plate receiver in the extended position. The significance of this is that charging plate transmitters are often typically located near a centerline or median plane of the vehicle or a vehicle's parking location. The vehicle's median plane divides the vehicle vertically through the centerline into essentially equal halves. However, the vehicle has powertrain components, including the engine, transmission, driveshaft, and axles, that occupy the underbody at and near the vehicle's median plane. Here, the use of the pivoting arm allows the stowed position to be offset from the vehicle's median plane. The offset can be greater than the size of the charging plate receiver so that the charging plate receiver does not intersect the vehicle's median plane.And the extended position can be centered on the median plane of the vehicle or intersect the median plane of the vehicle.

[0014] Fig. is an exemplary side view illustrating inductive charging pad locations on a vehicle. An inductive charging system 100 includes a vehicle 102, a receiver location 104 capable of supporting and receiving an inductive charging pad assembly, and a charging pad transmitter location 106 at which an inductive charging pad transmitter is configured to emit energy, such as electromagnetic energy, to be received by the charging pad receiver when the charging pad receiver is in an extended position, such as extended position 110. A first embodiment is illustrated in which a charging pad assembly location 104A is located near the center or passenger area of ​​a vehicle, thereby enabling a vehicle to be inductively coupled to a charging pad transmitter located at a central location 106A of a charging station parking space.A second embodiment is illustrated in which a charge plate assembly position 104B is located near the engine compartment, allowing a vehicle to be inductively coupled to a charge plate transmitter located at a forward position 106B of a charging station parking space. A third embodiment is illustrated in which a charge plate assembly position 104C is located near the rear of a vehicle, allowing a vehicle to be inductively coupled to a charge plate transmitter located at a rear portion 106C of a charging station parking space. Fig. also illustrates a ground clearance line 112 above which the charge plate receiver is stowed when in the retracted position. The charge plate receiver moves below the ground clearance line 112 when extended. For example, a charge plate may travel along an arc 114 to move from a retracted position to the extended position 110 for coupling with a charge plate transmitter located at the rear portion 106C of a charging station parking space.

[0015] Fig. is an exemplary rear view illustrating inductive charging pad positions on a vehicle. The inductive charging system 100 includes a vehicle 102, a receiver position 104 capable of supporting and receiving an inductive charging pad assembly, and a charging pad transmitter position 106. In one embodiment, both a charging pad assembly position 104D and a charging pad transmitter position 106D are positioned to intersect the median plane of the vehicle 102. In another embodiment, the charging pad transmitter position 106D is positioned to intersect the median plane of the vehicle 102, and a charging pad assembly position 104D is offset from the median plane 108 such that the charging pad receiver does not intersect the median plane 108.In this embodiment, the charging plate receiver would need to be pivoted along an arc 116 when moved between a stowed position and an extended position 104E in order to couple with the charging plate transmitter located at position 106D.

[0016] Fig. is an exemplary rear view illustration of an inductive charging plate receiver assembly 200 in an extended and a retracted position. This exemplary assembly includes a frame 202, a rail 204 attached to the frame 202, and an actuator 206. The actuator may be electric, hydraulic, or pneumatic. Examples of an electric actuator, also referred to as an electric machine, include an electric motor, a solenoid, and a linear actuator. The actuator 206 is operatively coupled to the rail 204 and the pivot arm 208 to enable movement of a charging plate receiver 210 between a stowed position and an extended position via the use of a connector 212. The frame 202 may be a rigid structure of the vehicle with mounting brackets for attaching the other parts.This assembly may be configured to form a four-arm system in which the frame 202 forms the base, the rail 204 and actuator 206 form the crank, the pivot arm 208 forms the rocker or follower, and the load plate receiver 210 forms the coupling or connecting rod. Other embodiments may include a five-arm linkage, a six-arm linkage, or other linkage construction. Use of the linkage construction provides a mechanism by which the load plate receiver can be extended below a ground clearance line of a vehicle 216. The ground clearance level of the vehicle 216, also referred to as the vulnerability line, is a predetermined distance above a horizontal plane on which the vehicle's wheels travel. When the assembly is in the extended position, the load plate 210 is oriented so that a principal plane of the receiver plate 210 is parallel to a load plate transmitter 214.The charging plate transmitter 214 is typically mounted in the floor so that the charging plate transmitter 214 and the charging plate receiver 210 are parallel to the floor.

[0017] When the load plate receiver 210' and the pivot arms 208A' and 208B' are in the retracted position, they are above the ground clearance level 216 of the vehicle. The load plate receiver 210' is in a final orientation when in the retracted position. The final orientation may include an orientation perpendicular to the ground or an angle typically greater than 45 degrees from the ground. A side orientation of the load plate receiver 210 is rotated from the final orientation. The transition from end to side includes a rotation in the orientation of the load plate receiver 210 of approximately 90 degrees as the load plate receiver 210' moves from the extended to the retracted position. The load plate receiver 210' is primarily constructed of a copper coil, but may include other conductive or ferromagnetic materials and is shown as square, but may also have a rectangular, circular, or other shape.

[0018] Fig. is an exemplary side view illustration of an inductive charging plate receiver assembly 220 in an extended and a retracted position. This exemplary assembly includes a frame 202, a rail 204 attached to the frame 202, and an actuator 206. The actuator may be electric, hydraulic, or pneumatic. Examples of an electric actuator, also referred to as an electric machine, include an electric motor, a solenoid, and a linear actuator. The actuator 206 is operatively coupled to the rail 204 and the pivot arm 208 to enable movement of a charging plate receiver 210 between a stowed position and an extended position through the use of a connector 212. The frame 202 may be a rigid structure of the vehicle with mounting brackets for attaching the other parts.This assembly may be configured to form a four-arm system in which the frame 202 forms the base, the rail 204 and actuator 206 form the crank, the pivot arm 208 forms the rocker or follower, and the load plate receiver 210 forms the coupling or connecting rod. Other embodiments may include a five-arm linkage, a six-arm linkage, or other linkage construction. Use of the linkage construction provides a mechanism by which the load plate receiver can be extended below a vehicle's ground clearance line 216. The vehicle's ground clearance level 216, also referred to as the line of vulnerability, is a predetermined distance above a horizontal plane on which the vehicle's wheels travel. When the assembly is in the extended position, the load plate 210 is oriented so that a principal plane of the receiver plate 210 is parallel to a load plate transmitter 214.The charging plate transmitter 214 is typically mounted in the floor so that the charging plate transmitter 214 and the charging plate receiver 210 are parallel to the floor.

[0019] When the load plate receiver 210' and the pivot arms 208A' and 208B' are in the retracted position, they are above the ground clearance level of the vehicle 216. The load plate receiver 210' is in an end orientation when in the retracted position. The end orientation may include an orientation perpendicular to the ground or an angle typically greater than 45 degrees from the ground. The end-to-side transition may include a rotation in the orientation of the load plate receiver 210 of approximately 90 degrees as the load plate receiver 210 moves from the extended to the retracted position. When the load plate receiver is in the retracted position 210', it may be retracted into a recess defined by underbody components. The underbody components may include a suspension and / or driveline section 222 and a muffler section 224.The assembly may be configured such that the pallet receiver 210' is adjacent to the area 222 when in the retracted position, and the pallet receiver 210 travels along an arc 230 to pivot below the area 222 when in the extended position. The orientation of the assembly may be such that the arc 230 is similar to the arc 114 of FIG. Fig. is oriented so that the charging plate receiver is located adjacent to the powertrain components that include an engine, transmission, drive shaft, or electric machine when the assembly is retracted, not intersecting the median plane 108 of the vehicle. And the charging plate receiver may be below the powertrain component when the assembly is extended, thus intersecting the median plane 108 of the vehicle. In another embodiment, the orientation of the assembly may be such that the arc 230 is similar to the arc 116 of Fig. is aligned: The load plate receiver, when retracted, may be located adjacent to the driveline components that include a rear axle or differential, and the recess may be located between the driveline component and a trunk of the vehicle or a muffler 224. And the load plate receiver may be below the driveline components 222 when extended.

[0020] Fig.is an exemplary illustration of a side view of an alternative inductive charging plate receiver assembly in an extended and retracted position. This exemplary assembly includes a frame 302, a rail 304 attached to the frame 302, and an actuator 306. The actuator may be electric, hydraulic, or pneumatic. Examples of an electric actuator, also referred to as an electric machine, include an electric motor, a solenoid, and a linear actuator. The actuator 306 is operatively coupled to the rail 304 and the pivot arm 308 to enable movement of a charging plate receiver 310 between a stowed position and an extended position using a connector 312. The frame 302 may be a rigid structure of the vehicle with mounting brackets for attaching the other parts.This assembly can be configured to form a four-arm system, with frame 302 forming the base, rail 304 and actuator 306 forming the crank, pivot arm 308 forming the rocker or follower, and load plate receiver 310 forming the coupling or connecting rod. Other embodiments can include a five-arm linkage, a six-arm linkage, or other linkage design. Use of the linkage design provides a mechanism by which the load plate receiver can be extended below a vehicle's ground clearance line 316. The vehicle's ground clearance level 316, also referred to as the line of vulnerability, is a predetermined distance above a horizontal plane on which the vehicle's wheels travel. When the assembly is in the extended position, load plate 310 is oriented so that a principal plane of receiver plate 310 is parallel to a load plate transmitter 314.The load plate transmitter 314 is typically mounted in the floor so that the load plate transmitter 314 and the load plate receiver 310 are parallel to the floor. The assembly 300 may include a linear actuator 318. When the load plate 310 is extended, the linear actuator 318, such as a cylindrical cam, may be used to adjust the position of the load plate receiver 310 relative to the load plate transmitter 314. The linear actuator 318 may cooperate with a sliding mechanism 320 to enable horizontal translation of the load plate receiver 310. The assembly 300 may also include a linear actuator 326 used to provide vertical translation of the load plate receiver 310.Vertical translation may allow the assembly 300 to position the charging plate receiver 310 closer to the charging plate transmitter 314 to increase the efficiency of energy transfer between the transmitter 314 and receiver 310.

[0021] When the pallet receiver 310' and the pivot arm 208' are in the retracted position, they are above the ground clearance level of the vehicle 316. The pallet receiver 310' is in an end orientation when in the retracted position. The end orientation of the pallet receiver 310 is rotated in this illustration from a side orientation, also referred to as a horizontal orientation, when in the extended position. The transition from end to side represents a rotation in the orientation of the pallet receiver 310 of approximately 90 degrees as the pallet receiver 310' moves from the extended to the retracted position. The pallet receiver 310' is shown as square, but it may also have a rectangular, circular, or other shape.

Claims

[1] Vehicle (102) comprising: an inductive charging plate arrangement arranged in a recess of the vehicle (102) and comprising a pivot arm (208) pivotally mounted on a mounting surface, and a loading plate receiver (210) pivotally mounted on the pivot arm (208) such that the loading plate receiver (210) changes from an end to a side orientation and travels along an arc (230) defined by a length of the pivot arm (208) as the assembly moves between a retracted position within the recess and an extended position below the recess, characterized by , that the lateral orientation of the pallet receiver (210) is rotated from the final orientation, the pallet receiver (210) has a flat surface, the flat surface being generally parallel to a horizontal plane of the vehicle (102) when the assembly is in the extended position, and wherein the pallet receiver (210) is offset from a median plane (108) of the vehicle (102) when the assembly is in the retracted position, and the pallet receiver (210) intersects the median plane (108) when the assembly is in the extended position. [2] The vehicle (102) of claim 1, further comprising an electric machine configured to move the assembly between the retracted and extended positions. [3] The vehicle (102) of claim 1, wherein the planar surface is generally perpendicular to the horizontal plane of the vehicle (102) when the assembly is in the retracted position. [4] The vehicle (102) of claim 1 or 3, wherein the assembly further comprises a drive arm and wherein the assembly consists of a four-arm linkage. [5] The vehicle (102) of claim 4, wherein the pivot arm and the drive arm each comprise a linear actuator. [6] The vehicle (102) of any of claims 1-5, wherein the loading plate receiver (210) is laterally adjacent to a vehicle component when the assembly is in the retracted position, and the loading plate receiver (210) is partially beneath the vehicle component when the assembly is in the extended position. [7] Vehicle (102) comprising: an inductive charging plate arrangement comprising a pivot arm (208) pivotally mounted on a mounting surface, and a pallet receiver (210) pivotally mounted on the pivot arm (208) such that the pallet receiver (210) is disposed within a recess defined by an underbody of the vehicle (102) when the assembly is retracted and travels along an arc (230) defined by a length of the pivot arm (208) when the assembly moves between the retracted and extended positions, wherein the pallet receiver (210) has a planar surface, the planar surface being generally parallel to a horizontal plane of the vehicle (102) when the assembly is in the extended position, and wherein the planar surface is generally perpendicular to the horizontal plane of the vehicle (102) when the assembly is in the retracted position. [8] The vehicle (102) of claim 7, further comprising an electric machine configured to move the assembly between the retracted and extended positions. [9] The vehicle (102) of claim 7 or 8, wherein the inductive charging plate assembly further comprises a drive arm, and wherein the inductive charging plate assembly forms a four-arm linkage. [10] The vehicle (102) of any of claims 7-9, wherein the recess is offset from a median plane (108) of the vehicle such that the loading plate receiver (210) does not intersect the median plane (108) when the assembly is in the retracted position, and the loading plate receiver (210) intersects the median plane (108) when the assembly is in the extended position. [11] The vehicle (102) of any of claims 7-9, wherein the recess is located adjacent to a trunk of the vehicle (102).

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