Alignment structure for a wireless charging station

Abstract

Wheel guide (26) for a vehicle charging station (16), comprising: a front (40) and a back (38); a top surface (32) extending between the front (40) and the back (38) and defining an opening (60) sized to enclose a wireless transmitter (20) of the charging station (16); and a pair of wheel slots (30) separated by a distance, the wheel slots (30) being recessed in the top (32) and each having an entrance (62), defined in the front side (40) and comprising a pair of longitudinal walls (42, 44) extending from the entrance (62) towards the rear side (38), characterized in that at least a portion of each of the walls is configured such that a slope of the wall is shallowest near the entrance (62) and becomes increasingly vertical in a direction toward the rear (38) to guide a wheel (28) of a vehicle 14 onto a centerline of the slot (30).

Description

TECHNICAL FIELD

[0001] The invention relates to a wheel guide for a vehicle charging station, comprising: a front and a rear side; a top side extending between the front and rear sides and defining an opening sized to enclose a wireless transmitter of the charging station; and a pair of wheel slots separated by a distance, the wheel slots being recessed in the top side and each comprising an entrance defined in the front side and a pair of longitudinal walls extending from the entrance toward the rear side. BACKGROUND

[0002] Battery-electric vehicles (BEVs) and plug-in hybrid electric vehicles (PHEVs) have a traction battery assembly that serves as the power source for the vehicle. The traction battery includes components and systems to help manage vehicle performance and operation. BEVs and PHEVs can be connected to a charging station to recharge the battery using power from the power grid or another external power source. US 5 821 731 A is known from the prior art. This describes a connection system and a connection method for charging an electric vehicle, which guides the electric vehicle to a charging position through a wheel guide, wherein the wheel guide has wheel slots whose sidewalls are oriented perpendicular to the ground.

[0003] The alignment of the wheels within the wheel slots in the transverse direction can vary depending on the driver's parking behavior, which causes positioning deviations between the primary charging unit of the charging station positioned in an opening of the wheel guide and the secondary charging unit of the vehicle, which gives rise to the possibility of charging being interrupted and increased charging losses.

[0004] It is an object of the invention to provide a wheel guide for a vehicle charging station which has an optimized positioning of the vehicle in order to enable an efficient charging process.

[0005] This is achieved according to the invention with a wheel guide for a vehicle charging station having the features of claim 1. SUMMARY

[0006] According to one embodiment, a wheel guide for a vehicle charging station includes a front and a rear side, and a top side extending between the front and rear sides. The top side defines an opening sized to enclose a wireless transmitter of the charging station. The wheel guide also includes a pair of wheel slots mounted at a distance from one another and recessed in the top side. Each wheel slot includes an entrance defined in the front side and a pair of longitudinal walls extending from the entrance toward the rear side. At least a portion of each of the walls is configured such that a slope of the wall is shallowest near the entrance and becomes increasingly vertical in a direction toward the rear side to guide a wheel of a vehicle onto the centerline of the slot.

[0007] According to another embodiment, a charging station for a vehicle includes a fork-shaped wheel alignment structure defining a pair of wheel slots, each having a pair of guide walls extending from an entrance to a terminal end. A portion of each of the walls is configured such that a slope of the wall is shallowest at the entrance and becomes increasingly vertical toward the terminal end. The charging station further includes a charging transmitter disposed below the alignment structure.

[0008] According to another embodiment, an alignment structure for a vehicle charging station includes a front and a rear side, and a top surface extending therebetween. A wheel guide is recessed in the top surface and includes a pair of longitudinal walls separated by a distance and each extending from the front side to the rear side. A portion of each of the walls is configured such that a slope of the wall is shallowest at the front side and becomes increasingly vertical toward the rear side. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a diagrammatic perspective view of an exemplary vehicle charging system. Fig. 2 is a perspective view of an alignment structure for the charging system. Fig. 3 is an enlarged perspective view of a portion of the alignment structure. Fig. 4 is a cross-sectional side view of the vehicle charging system according to one embodiment. Fig. 5 is a side view of the vehicle charging system according to another embodiment. DETAILED DESCRIPTION

[0009] Embodiments of the present disclosure are described herein. However, it is to be understood that the disclosed embodiments are only examples, and further embodiments may take various and alternative forms. The figures are not necessarily drawn to scale; some features may be greatly exaggerated or reduced to show details of particular components. Therefore, the specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a typical basis for teaching one skilled in the art how to variously employ the present invention.As will be understood by those skilled in the art, various features illustrated and described with respect to any of the figures may be combined with features illustrated in one or more other figures to produce embodiments not explicitly illustrated or described. The combinations of illustrated features provide representative embodiments of typical embodiments. However, for particular applications and implementations, numerous combinations and variations of the features may be desired consistent with the teachings of this disclosure.

[0010] Vehicles can be powered solely by battery electricity (e.g., BEVs) or by a combination of energy sources including battery electricity (e.g., PHEVs). PHEVs, for example, are powered by both a traction battery and an internal combustion engine. During vehicle use, energy stored in the traction battery is discharged to power the electric motor. The traction battery must be recharged regularly to restore energy after a discharge cycle. The vehicle can be charged using a charging station that is electrically connected to the power grid or another external power source.

[0011] In Fig. 1, a vehicle charging system according to one or more embodiments is illustrated and is generally designated by the numeral 10. Induction charging is used to transfer power from a charging station 16 to a vehicle 14 to recharge the battery. The vehicle 14 is shown coupled to the charging station 16. The charging station includes a vehicle charger 12. The vehicle charger 12 is connected to and receives its power from the electrical grid or another power source (e.g., a local solar power source).

[0012] The vehicle 14 includes a secondary coil housed in an induction charging plate 18, which in turn is disposed on the underside of the vehicle 14. The secondary induction charging plate 18 of the vehicle 14 is electrically connected to the traction battery of the vehicle 14. The vehicle 14 also includes an alternating current (AC) to direct current (DC) converter for rectifying and filtering the alternating current received from the vehicle charger 12 into a direct current to be received by the battery. The vehicle charger 12 may be disposed in the garage floor beneath the vehicle 14 or on one of the walls of the garage. The charger 12 includes a primary charging coil housed in a corresponding primary induction charging plate 20. The primary induction charging plate 20 may be generally horizontally and vertically offset from the secondary induction charging plate 18 of the vehicle 14.For example, plate 18 may be located above plate 20 in the charging position. In some embodiments, plate 20 is a wireless power transmitter and plate 18 is a wireless power receiver. The primary induction charging plate 20 may be adjustable in height to create a suitable gap between the plates (18, 20) that facilitates charging the vehicle 14. The electrical current is provided to the primary coil, which generates an electromagnetic field around the primary induction charging plate 20. When the secondary induction charging plate 18 is in close proximity to the powered primary induction charging plate 20, it receives power by being within the generated electromagnetic field. A current is induced in the secondary coil and subsequently transferred to the vehicle battery to charge the battery.The gap between the plates allows for variation of the vehicle alignment and also for the supply of alternatively registered vehicles with different ground clearance.

[0013] In an alternative embodiment (not shown), the primary induction charging plate is configured in a generally upright position—for example, on or near a wall. The vehicle has a corresponding secondary induction charging plate in a vertical position on the front or rear side, such as the front or rear bumper. The primary and secondary induction charging plates come into close proximity to each other when the vehicle is driven to the charging station and parked in a designated charging position.

[0014] The vehicle 14 is provided with a control unit 22. Although the vehicle control unit 22 is shown as a single control unit, it may include multiple control units used to control multiple vehicle systems. The vehicle control unit 22 may be, for example, a vehicle system controller / powertrain control module (VSC / PCM). In this regard, the vehicle 14 charging control portion of the VSC / PCM may be embedded as software within the VSC / PCM, or it may be a separate hardware unit. The vehicle control unit 22 generally includes any number of microprocessors, ASICs, ICs, memory (e.g., flash memory, ROM, RAM, EPROM, and / or EEPROM), and software code to cooperate with one another to perform a series of operations.A microprocessor in the vehicle control unit 22 also includes a timer for tracking specified time intervals between a time reference and selected events. Designated intervals are programmed so that the control unit provides specified command signals and monitors specified inputs at selectable time intervals. The vehicle control unit is in electrical communication with the vehicle battery and receives signals to indicate the battery charge level. The vehicle control unit 22 also communicates with other control units via a wired vehicle connection using a common bus protocol (e.g., CAN) and also employs wireless communication.

[0015] The vehicle charger 12 is provided with a charger control unit 24 having wireless communication elements. Similarly, the charger control unit 24 is embedded with software and is programmable to regulate the current flow provided by the vehicle charger 12. Software included in the vehicle control unit 24 may include a timer to track the elapsed time between designated events. Under selected conditions or upon receipt of designated commands, the charger control unit 24 may enable, disable, or decrease the current flow through the charger 12. The vehicle charger 12 is configured to receive signals indicative of charging commands from the vehicle control unit 22.

[0016] The charging station 16 also includes a wheel alignment structure or wheel guide 26, which is used to align the loading plate 18 on the vehicle 14 with the loading plate 20 of the charging station 16. The guide 26 is used to align the front wheels 28 of the vehicle 14 with respect to the loading plate 20 to ensure even and proper charging of the vehicle 14.

[0017] The Fig. 2 and Fig. 3 illustrate the alignment structure or guide 26 according to one or more embodiments. The guide 26 includes a top surface 32, a bottom surface 34, longitudinal sides 36, a back surface 38, and an input side 40. The guide 26 also includes a pair of wheel slots 30 or guides 26 extending from the input side 40 toward the back surface 38. The longitudinal centerline of the slots 30 may be substantially parallel to the longitudinal sides 36. Each of the wheel slots 30 may extend completely through the guide 26 and have an inner longitudinal wall 44 extending between the top surface 32 and the bottom surface 34 and an outer longitudinal wall 42 also extending between the top surface 32 and the bottom surface 34. In some embodiments, the wheel slots need not extend completely through the guide 26.Instead, the wheel slots 30 are recessed in the top surface 32 and have a depth that is less than the height of the guide 26. Each of the slots 30 may include a straight section 52 located generally in the target area 56 of the guide 26 and a tapered section 50 located in the entrance area 58. Within the straight area 52, the inner and outer walls 42, 44 are evenly spaced from each other. Within the tapered section 50, the distance between the inner and outer walls 42, 44 varies along the centerline in the longitudinal direction of the slot 30. The distance between the inner and outer walls 42, 44 is greatest at the entrance 62 of the slot 30, which is located on the entrance side 40 of the guide 26. The inner and outer walls 42, 44 are inwardly tapered (i.e.tapered toward each other) and the distance between the walls 42, 44 decreases uniformly in a forward direction of the slot 30 (i.e., from the entrance side 40 toward the rear side 38). Each of the walls 42, 44 has a transition point 64 at which the tapering ends and the walls extend substantially parallel to each other. The transition point 64 is located where the tapered section 50 and the straight section 52 meet.

[0018] The outer wall 42 may include a vertical surface 46 in the straight section 52 and an inclined surface 48 in the tapered section 50. The slope of the inclined surface 48 is shallowest at the entrance 62 of the tapered section 50. The inclined surface 48 becomes increasingly vertical in the forward direction. At the transition point 64, the tapered surface 48 is substantially vertical to match the vertical surface 46. The inclined surface 48 may have a slope of between 10 and 30 degrees relative to the ground on the entrance side 40 and gradually increase to approximately 90 degrees (i.e., vertical) at the beginning of the straight section 52. The inner wall 44 may be configured as described above with respect to the outer wall 42.

[0019] The slot 30 is tapered at the entrance 62 to facilitate guiding the vehicle wheels 28 into the slots 30. The width of the slots 30 on the entrance side 40 may be two or three times the width of the wheels 28 of the vehicle 14. The slot 30 gradually narrows—in the tapered section 50—to a width that approaches the width of the wheel 28, although slightly larger. The width of the slot 30 in the straight section 52 may, for example, be 5 to 25% wider than the width of the wheel 28.

[0020] The tapered shape of the slots 30 cooperates with the inclined surfaces 48 of the walls 42, 44 to assist in guiding the vehicle 14 into proper alignment with the transmitter 20. The inclined surfaces 48 include at least two mechanisms for guiding the wheels 28 toward the centerline of the slots 30. First, the inclined surfaces 48 can cause the wheels 28 to slide down the inclined surfaces 48 toward the centerline of the slots 30. The gradual increase in the slope of the inclined surface 48 also facilitates the sliding of the wheel 28 by providing increased lateral reaction forces on the wheel 28. Second, the inclined surfaces provide feedback to the driver of the vehicle 14, warning them to steer the vehicle 14 toward the centerline of the slot 30.For example, as the wheel 28 continues to travel forward along the inclined surface 48, the increasingly vertical inclination provides increasingly strong feedback to the driver and assists the driver in steering the wheels into the correct alignment in the slots 30. While the side walls 42, 44 of the slots 30 position the vehicle 14 laterally relative to the transmitter 20, the transverse wall 54 positions the vehicle 14 longitudinally.

[0021] The dimensions of the guide 26 vary according to the vehicle 14. An exemplary vehicle 14 may be configured with the loading plate 18 located directly behind the front axle. Here, the longitudinal sides 36 may extend from directly in front of the front axle to approximately the B-pillar of the vehicle 14. The spacing between the pair of slots 30 depends on the track width of the front wheels 28. The spacing between the slots 30 may be adjustable to accommodate different vehicle models. The thickness between the top 32 and the bottom 34 (i.e., the height) of the guide 26 may range from 2 to 10 inches, depending on the vehicle 14 and the desired spacing between the plates 18, 20. The guide 26 may be made of metal or a composite material. In some embodiments, the guide 26 may include anchors to securely position the guide 26 on the ground.The anchors may be fasteners or a non-slip surface on the underside 34.

[0022] In Fig. 4, in an exemplary charging station 16, the transmitter 20 is disposed in or beneath the concrete or dirt-resistant floor 66. The guide 26 is mounted on top of the floor 66. The guide 26 includes a hole (opening) 60 disposed above the transmitter 20. The hole 60 allows the wireless signal from the transmitter 20 to be transmitted to the receiver 18 on the vehicle 14. The hole 60 is sized to encompass the transmitter 20. The transmitter 20 may be connected to the charger 12 via one or more cables 68.

[0023] In Fig. 5, another charging station 70 is shown. The charging station 70 includes an alignment structure or guide 72 disposed on the floor 74. In this charging station, the transmitter 76 is disposed within the guide 72. The guide 72 may have additional height to accommodate the transmitter 76 and electronics 78. The electronics 78 may be connected to the charger via one or more cables 80. The guide 72 may include a hole 82 disposed above the transmitter 76 to allow proper communication between the transmitter 76 and the receiver 18 on the vehicle 14. The guide 72 may include wheel slots similar to the wheel slots 30 of the guide 26.

[0024] An exemplary running-in process will now be described with reference to the Fig. 1 and Fig.2. The guide 26 is positioned on the floor in proper alignment with the transmitter 20, which may be on the floor or on the wall. The guide is positioned so that the entry side 40 faces the garage door opening. When driving into the garage, the vehicle 14 approaches the guide 26 in a forward travel (i.e., not a reverse travel). The driver attempts to position the front wheels 28 on the centerline of the slots 30, and the wheels 28 enter the tapered portion 50 of the slots 30 as the vehicle 14 moves forward. Depending on the skill of the driver, the wheels 28 may be properly aligned and on the floor, or they may be partially on the interior or exterior walls 42, 44.The walls of each slot 30 cooperate to guide the wheels 28 toward the centerline of the slots 30 as the driver continues to advance toward the rear side 38 of the guide 26. As the driver continues to advance, the wheels 28 impact the rear walls 54, signaling the driver to stop forward movement and park the vehicle 14. In a proper parking position, each of the wheels 28 is disposed between the inner and outer walls 42, 44 of the straight section 52, and the leading edge of the tire rests against or near the transverse wall 54.

[0025] Although exemplary embodiments have been described above, these embodiments should not be construed as describing all possible forms encompassed by the claims. The terms used in this specification are terms of description, not limitations, and it is understood that numerous changes may be made without departing from the spirit and scope of the disclosure. As described above, the features of various embodiments may be combined to form further embodiments of the invention not expressly described or illustrated.Although various embodiments may have been described as providing advantages or being preferred over other prior art embodiments or implementations with respect to one or more features, those skilled in the art will recognize that one or more features may be included to achieve the desired overall system characteristics, each depending on the specific application and implementation. These features may include, but are not limited to, cost, durability, life cycle cost, merchantability, appearance, packaging, size, convenience, weight, manufacturability, ease of assembly, etc.Therefore, embodiments that have been described as less desirable than other embodiments or prior art implementations with respect to one or more characteristics are not outside the scope of the disclosure and may be desirable for particular applications.

[0026] It is further described: A. Wheel guidance system for a vehicle charging station, comprising: a front and a back; a top surface extending between the front and back surfaces and defining an opening sized to enclose a wireless transmitter of the charging station; and a pair of wheel slots separated by a distance, the wheel slots being recessed in the top and each including an entrance defined in the front side and a pair of longitudinal walls extending from the entrance toward the rear side, at least a portion of each of the walls being configured such that a slope of the wall is shallowest near the entrance and becomes increasingly vertical in a direction toward the rear to guide a wheel of a vehicle onto a centerline of the slot. B. Wheel guide according to A, wherein each of the wheel slots comprises a tapered section near the front in which the longitudinal walls are offset by a variable horizontal width and a uniform section near the rear in which the longitudinal walls are offset by a substantially constant horizontal width. C. Wheel guide according to B, wherein the inclination of the wall is variable in the tapered section and is substantially constant and vertical in the uniform section. D. Wheel guide according to A, wherein each of the wheel slots further comprises an end wall extending between the longitudinal walls. E. Wheel guide according to A, wherein the longitudinal walls extend vertically between the top and bottom of the wheel guide. F. Charging station for a vehicle, comprising: a fork-shaped wheel alignment structure defining a pair of wheel slots each having a pair of guide walls extending from an entrance to a terminal end, a portion of each of the walls being configured that a slope of the wall is flattest at the entrance and becomes increasingly vertical towards the terminal end; and a charging transmitter located under the alignment structure. G. The loading station of F, wherein each of the wheel slots includes a tapered portion near the entrance in which the guide walls are offset by a variable horizontal width, and a uniform portion near a rear side of the alignment structure in which the guide walls are offset by a substantially constant horizontal width. H. A charging station according to G, wherein the inclination of the wall is variable in the tapered section and is substantially constant and vertical in the uniform section. I. Charging station according to F, wherein the alignment structure defines an opening and wherein the charging transmitter is arranged below and enclosed by the opening. J. The charging station of F, wherein each of the guide walls extends vertically between a top and a bottom of the alignment structure. K. The charging station of claim 1, wherein the alignment structure defines an opening positioned to allow an inductive charging signal from the charging transmitter to pass through the opening. L. Charging station according to F, wherein the charging transmitter is arranged in the alignment structure. M. The charging station of claim 1, wherein the alignment structure defines an opening positioned over the charging transmitter and configured to allow an inductive charging signal to traverse the opening. N. Charging station according to L, further comprising a charger electrically connected to a power grid and configured to send power to the charging transmitter. O. Alignment structure for a vehicle charging station, comprising: a front and a back and a top extending therebetween; and a wheel guide recessed in the top and comprising a pair of longitudinal walls separated by a distance and each extending from the front to the rear, a portion of each of the walls being configured such that a slope is shallowest at the front and becomes increasingly vertical toward the rear. P. The alignment structure of O, wherein each of the wheel guides includes a tapered portion near the front side in which the longitudinal walls extend converging toward each other in a forward direction, and a uniform portion near the rear side in which the longitudinal walls have a constant lateral spacing relative to each other. Q. Alignment structure according to P, wherein the slope of the wall is variable in the tapered section and constant and vertical in the uniform section. R. Alignment structure according to O, wherein the top defines an opening sized to enclose a wireless transmitter of the charging station. S. The alignment structure of claim 0, including a wireless charging transmitter disposed between the top and bottom of the alignment structure.

Claims

[1] Wheel guide (26) for a vehicle charging station (16), comprising: a front (40) and a back (38); a top surface (32) extending between the front (40) and the back (38) and defining an opening (60) sized to enclose a wireless transmitter (20) of the charging station (16); and a pair of wheel slots (30) separated by a distance, the wheel slots (30) being recessed in the top (32) and each having an entrance (62), defined in the front side (40) and comprising a pair of longitudinal walls (42, 44) extending from the inlet (62) towards the rear side (38), characterized byin that at least a portion of each of the walls is configured such that a slope of the wall is shallowest near the entrance (62) and becomes increasingly vertical in a direction toward the rear (38) to guide a wheel (28) of a vehicle 14 onto a centerline of the slot (30). [2] Wheel guide (26) according to claim 1, wherein each of the wheel slots (30) comprises a tapered section (50) near the front side (40) in which the longitudinal walls (42, 44) are offset by a variable horizontal width, and a uniform section (52) near the rear side (38) in which the longitudinal walls (42, 44) are offset by a substantially constant horizontal width. [3] Wheel guide (26) according to claim 2, wherein the inclination of the wall is variable in the tapered section (50) and is substantially constant and vertical in the uniform section (52). [4] The wheel guide (26) of claim 1, wherein each of the wheel slots (30) further comprises an end wall (54) extending between the longitudinal walls (42, 44). [5] Wheel guide (26) according to claim 1, wherein the longitudinal walls (42, 44) extend vertically between the top (32) and the bottom (34) of the wheel guide (26).

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