An Electric Vehicle Charging Plug

Abstract

An electric vehicle charging plug, 10’ for controlling a motorised charging cable dispensing and retracting apparatus, the plug comprising a handheld plug body 14, 16, 18, comprising a connector end f

Description

02 06 25 The present invention relates to an electric vehicle charging plug for controlling a motorised electric vehicle charging cable dispensing and retracting apparatus. BACKGROUND TO THE INVENTION 5 Some electric vehicle chargers include an in-built charging cable which extend from an electric vehicle charger enclosure. There are a number of ways in which the charging cable is stored, for example in a coiled configuration or hanging freely from the enclosure. Other electric vehicle chargers include a charger socket for receiving a plug of a 10 charging cable, in such cases the electric vehicle owner will need a separate charging cable which terminates with a plug at either end, i.e., a plug to connect to the electric vehicle charger and a plug to connect to the electric vehicle. The separate charging cable will usually be stored loose within the electric vehicle. The charging cable will usually be deployed manually. Taking the electric vehicle 15 charger with an in-built cable for example, the user will pull the cable towards a charging socket of the electric vehicle to extend the cable from the stored position, and then retract the cable back to the stored position after use. This may require the cable to be manually coiled or guided around a charging cable store such as a cable drum. This may be difficult because the weight and length of the cable makes them 20 cumbersome, especially for individuals with disabilities or physical difficulties. Furthermore, the user has to make sure that the plug does not get damaged while they manually extend and retract the cable. This may add difficulty to handling the cable since the weight, size and shape of the plug may not make it easier for some users, especially those with disabilities or physical difficulties, to hold while pulling the cable. 25 In some instances, either during charging or after charging, the cable is in an extended position along the ground. This may be because too much cable has been extended or it is troublesome to store the cable, especially for those with disabilities or physical difficulties. In the extended position there is a potential for the user to trip over the cable especially at night when it is dark. Furthermore, the cable could be at risk of damage 30 from being driven over by a vehicle. Users may be in a hurry or may not take the time to handle the plug and cable with proper care. Therefore, they may pull the cable in a harsh manner which could damage 02 06 25 and / or tangle the cable further after every use. This means that an operator may be required to come to the charger to fix and untangle the cable. At times, this may also require the cable to be replaced in cases where it is completely damaged and / or unsafe to use. 5 Consequently, there is a need to improve electric vehicle charging cables to increase accessibility and safety. It is an object of the present invention to reduce or substantially obviate the aforementioned problems. STATEMENT OF INVENTION 10 According to the first aspect of the present invention there is provided an electric vehicle charging plug for controlling a motorised charging cable dispensing and retracting apparatus, the plug comprising: a handheld plug body comprising a connector end for connecting to a charging socket of an electric vehicle and a cable end; and 15 a control input means disposed on or in the handheld plug body and connected to a controller for remotely controlling the motorised charging cable dispensing and retracting apparatus, wherein the controller is adapted to interpret the operation of the control input means and generate a signal for extending or retracting a charging cable using a motor of the motorised charging cable dispensing and retracting apparatus, in 20 which the controller is adapted to control the speed of the motorised charging cable dispensing and retracting apparatus based on the operation of the control input means, and in which the extent of travel of the control input means is interpreted as a desired motor speed by the controller. Advantageously, the plug or system provides for a simple and straightforward means 25 to dispense an electric vehicle charging cable because it allows the user to operate a motor from the plug. The control input means on the plug is intuitive to a user which allows an unfamiliar user to easily understand how it is operated. The plug can be considered an accessibility plug or accessible plug because it may make the process of using an electric vehicle charger more accessible to users 30 especially those with disabilities or physical difficulties. The provision of the plug on an end of a cable provides a location which can easily be reached especially by people with disabilities or physical difficulties for example, a person in a wheelchair. This 02 06 25 improves the accessibility of the electric vehicle charger to users since the plug is within reach for everyone. The controller may be a processor. The handheld plug body may comprise a main body element, a connector end element 5 and a cable end element. The main body element may be substantially cylindrical in shape. A flat side may be provided in the handheld main body, preferably the main body element. The flat side may be facing the user when in use. The main body element may be a shell. The plug may comprise an AC or a DC connector. 10 The connector end element and the main body element may be made from a substantially rigid material such as a metal or plastic. This allows the plug to support its components and allows the user to hold the plug to connect to the charging socket of the electric vehicle for charging. The handheld plug body, preferably the main body element, may have a substantially 15 curved shape. The curved shape may be provided with a curvature suitable for gripping by a user. The curved shape allows the user to hold the plug by the handle more comfortably while connecting the plug to the charging socket. This is because the user does not have to reposition their hand on the plug when plugging it into the charging socket. 20 The main body element may be disposed between the connector end element and the cable end element. The plug may include a shoulder at the end of the handheld body next to the connector end. In use, the shoulder may abut an outer surface of the charging socket while the connector end is slotted into the charging socket of the electric vehicle. 25 The cable end, preferably the cable end element, may be made from a substantially durable and pliable material such as rubber to allow flexing or bending. This prevents the cable from being damaged when the user is handling the plug. Preferably, the control input means may be provided on the flat side of the handheld main body. This allows the user to hold the plug without accidentally pressing the 30 control input means. This means that the user is less likely to make a mistake with extending or retracting the charging cable. 02 06 25 The control input means may be a touch screen. The touch screen may be provided with at least one icon, such as a button, which is used to operate the motor. The control input means may be a capacitive button. The capacitive button may be a capacitive switch. The capacitive button may operate in a fashion similar to some of 5 the other control input means mentioned below. The control input means may be a slider knob. The slider knob may comprise a variable resistor in which the resistance changes based on the rectilinear movement of the slider knob. The slider knob may have a rest position, preferably a central position. The rest position may be the position in which there is no input. The slider knob may be 10 biased to a rest position. The control input means may be a rotatable knob. The rotatable knob may comprise a variable resistor in which the resistance changes based on the rotational movement of the rotatable knob. The rotatable knob may have a rest position. The rest position may be the position in which there is no input. The rotatable knob may be biased to a 15 rest position. The control input means may be a switch. The switch may be a pushbutton switch. The switch may be a momentary switch. There may be a switch for the extension of the charging cable and another switch for the retraction of the charging cable. 20 The control input means may be a rocker switch. The rocker switch may have two positions, wherein the first position is for retraction and the second position is for extension. The rocker switch may be a biased rocker switch for biasing the switch into a stop position. The rocker switch may be biased into a third position, i.e., the stop position. 25 The stop position may be a central position. The controller may be adapted to stop the motor when the rocker is in the stop position. To put it another way, the rocker may be biased to a position where the controller interprets there is no input from the control input means. The rocker switch may be a momentary rocker switch, i.e., constant operation of the 30 switch in either position is needed. 02 06 25 The control input means is a single axis joystick. The single axis joystick may have a first position and a second position. In the first position the controller may be adapted to cause the motor to dispense, i.e., extend, the charging cable. In the second position the controller may be adapted to cause the motor to retract the charging cable. 5 The single axis joystick may be biased towards a stop position. The stop position may be a central position. The stop position may be considered the rest position of the single axis joystick. The controller is adapted to stop the motor when the single axis joystick is in the central position. To put it another way, the joystick may be biased to a position where the controller interprets there is no input from the control input means. 10 When the user operates the control input means, the controller may interpret the operation of the control input means. Based on the operation of the control input means the controller may send a signal to a motor in the electric vehicle charger to allow the charging cable to extend or retract from a cable store. Put another way, the controller may control the extension and retraction of the charging cable from the cable store of 15 the electric vehicle charger. The control input means may comprise a tilt sensor. The control input means may comprise an inertial measurement unit. An operator presence control means may be provided. The operator presence control means may be connected to the controller. The controller may be adapted to stop the 20 motor when the operator presence control means determines that the operator no longer grips the handheld plug body. The operator presence control means may comprise a biased mechanical actuator. The mechanical actuator may be disposed on or in the handheld plug body. The biased mechanical actuator may be biased to a position which represents that the operator no 25 long grips the handle. The operator presence control means may comprise a sensor. The sensor may be a pressure sensor. The sensor may be disposed in a position which will be gripped by an operator. The sensor may be a presence sensor. The sensor may be an accelerometer. The sensor may be an I MU. 30 The sensor, preferably the pressure sensor, may be disposed in a grip. 02 06 25 By providing an operator presence control means it is possible to incorporate a dead man’s switch into the plug or system. This ensures that the motor will stop working should the plug be accidently dropped or there is a loss of grip. The controller is adapted to control the speed of the motorised charging cable 5 dispensing and retracting apparatus based on the operation of the control input means. That is to say the controller interprets the operation of the control input means to determine the speed of motor rotation and direction of motor rotation. The travel of the control input means is used by the controller to interpret the desired motor speed. For example, the controller will interpret the travel of the single axis 10 joystick from the rest position as representing the desired speed of the motor. A wireless communication means may be provided. The signal being sent by the controller to the charging cable store may be a wireless signal. A wireless relay, or a relay connected to a wireless communication means, may be connected to the controller. The relay, or wireless relay, may be provided in the electric 15 vehicle charger. Advantageously, this allows the electric vehicle charger to be retrofitted to have an automatic cable store function for the extension and retraction of the charging cable. A wired communication means may be provided. The wired communication means may communicate the signal through a communication wire. The communication wire 20 may be provided in the electric vehicle charging cable. Advantageously, this is a cheaper solution to automate the extension and retraction of the charging cable from the electric vehicle charger. A display may be provided on the main body of the plug. The display may be a screen. The screen may provide written or visual instructions on how to use the electric vehicle 25 charger. For example, the display means may provide a step-by-step walkthrough of the process. Additionally, the display means may provide information or a live update on the amount of used electricity or used energy while the vehicle is charging. The display may have touchscreen functionality. The display may be disposed on a flat section of the handheld plug body. This allows 30 the user to see the display screen to follow the instructions or see the information while holding the plug without covering it with their hand(s). The display may extend from a portion of the handheld plug body. 02 06 25 An audio means, such as a speaker, may be provided on the handheld plug body. The audio means may be disposed on a flat section of the handheld plug body. This prevents the audio means from being covered by the user’s hand(s) when using the 5 plug. The audio means may provide the audio instructions on how to use the electric vehicle charger. The audio means may complement the display means such that the audio matches the instructions provided on the display means. An indicator light may be provided on the handheld plug body. Preferably, the indicator light may be disposed on a flat side handheld plug body. This prevents the indicator 10 light from being covered by the user’s hand(s) when using the plug. The indicator light may provide the status of the movement of the charging cable, the status of the electric vehicle charger and / or the status of the charge of the electric vehicle. A handle portion of the handheld plug body may have a reduced diameter. The handle portion may be sized and shaped so as to allow an individual to grip the handle. This 15 allows the plug to be easily held since the user would not need both hands to hold the plug if preferred. A grip may be provided on the handle portion. The grip may be disposed on the opposite side of the flat side of the handheld plug body. The grip allows the fingers of the user’s hand(s) to hold onto the plug better making it easier to handle the plug and 20 minimise the risk of accidentally dropping the plug. According to a further aspect of the present invention there is provided an electric vehicle charging cable dispensing and retracting system, the system comprising an electric vehicle charging plug as set out in the first aspect of the present invention disposed at one end of an electric vehicle charging cable and a motorised charging 25 cable dispensing and retracting apparatus, the apparatus comprising: a charging cable store for storing the charging cable; and an electric motor for extending or retracting the electric vehicle charging cable to or from the store. The cable store may be a charging cable drum onto which the charging cable is wound. According to another aspect of the present invention there is provided a method for 30 dispensing or retracting an electric vehicle charging cable, the steps comprising: taking a plug according to the first aspect of the present invention from its position on an electric vehicle charger; 02 06 25 operating the control input means on the plug to extend a charging cable away from a charging cable store; plugging a connector end of the plug into a charging socket for charging an electric vehicle; 5 unplugging the connector end of the plug from the charging socket after charging the electric vehicle; operating the control input means on the plug to retract the charging cable towards the electric vehicle charger; and placing the plug back to its position on the electric vehicle charger. 10 The method may also comprise the step of providing a system according to a further aspect of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS For a better understanding of the present invention, and to show more clearly how it may be carried into effect, reference will now be made by way of example only to the 15 accompanying drawings, in which: Figure 1 shows a perspective view of a first embodiment of a plug for an electric vehicle charging cable; Figure 2 shows a side view of a second embodiment of a plug for an electric vehicle charging cable; 20 Figure 3 shows a perspective view of an electric vehicle charger comprising the plug shown in Figure 1 connected to a charging cable in a retracted position; Figure 4 shows a further perspective view of the electric vehicle charger in Figure 3 but with the charging cable in an extended position; Figure 5 shows cross sectional view of the electric vehicle charger in Figures 3 and 4; 25 and Figure 6 shows a schematic drawing of the electric vehicle charger in Figures 3 to 5. DESCRIPTION OF PREFERRED EMBODIMENTS 02 06 25 Referring firstly to Figure 1, an accessible plug suitable for an electric vehicle charger is indicated at 10. The plug 10 has a substantially cylindrical shape with a flat side 12. In use, the flat side 12 is the part of the plug 10 that faces the user. The plug 10 comprises a connector 5 end element 14, a cable end element 16 and a main body element 18. The main body element 18 is made from a substantially rigid material such as a metal or plastic. The connector end element comprises at least a portion, preferably the outer wall, which is made from a substantially rigid material, preferably the same material as the main body element. This allows the components of the plug 10 to be supported 10 and allows the user to be able to hold the plug to connect to a charging socket of an electric vehicle (not shown). The connector end element 14 includes a connector 20. The connector 20 includes a number of conductive contacts for AC or DC power for charging the electric vehicle. In some embodiments, conductive contacts may also be provided for carrying signals. 15 The connector 20 is mainly disposed within the connector end element 14 but may also partly extend into the main body element 18. The connector end element 14 and the connector 20 together are slotted into the charging socket of the electric vehicle for charging, where the connector end element 14 and the connector 20 complement the shape of the charging socket of the electric vehicle. 20 The cable end element 16 is disposed on the opposite end of the plug 10 to the connector end element 14. The cable end element 16 receives a charging cable 42 of the electric vehicle charger 44 (shown in Figures 3 and 4). The cable end element 16 is made from a substantially pliable material such as rubber. In such cases, the cable end element may be considered a strain relief means. In other 25 embodiments, a strain relief means may be provided on the cable end element 16. In the current embodiment, the strain relief means has a plurality of interconnected flexible ribs which allows the charging cable 42 to be able to flex or bend within the cable end element 16. This prevents the charging cable 42 from being damaged while the user controls the extension or retraction of the charging cable 42 from the electric 30 vehicle charger 44, and while the user positions the plug 10 in the charging socket of the electric vehicle. The main body element 18 is disposed between the connector end element 14 and the cable end element 16. The main body element 18 acts as a housing for enclosing part 02 06 25 of the connector 20, part of the charging cable 42 and other components of the plug 10. The main body element 18 is substantially curved. The main body element 18 is formed from a two-part shell. The first part 22 and the second part 24 are connected together 5 to form the shell. A portion of both parts of the shell are curved and form a curved section 26. The connector end element 14 has a smaller cross-sectional area than the portion of the main body element 18. From this, a shoulder 28 is formed between the connector end element 14 and the main body element 18. The shoulder 28 abuts an outer surface 10 of the charging socket of the electric vehicle while the connector end element 14 are slotted into the charging socket of the electric vehicle. A handle portion 30 is formed in the body of the handheld plug 10. The handle portion 30 is recessed into the main body element 18. The handle portion 30 includes a grip 32 which, in use, is disposed on the side of the 15 plug 10 opposite the flat side 12 which faces away from the user. The grip 32 allows the fingers of the user to get a better hold of the plug 10 minimising the risk of dropping the plug 10. An operator presence control means (33, Figure 6) may comprise a pressure sensor disposed under the grip 32 and within the handle portion 30. The sensor may be 20 coupled to a controller (35, Figure 6). A control input means 34 is provided on or in the main body element 18, preferably the flat side 12. This allows the user to see their input for controlling the movement of the charging cable 42. The control input means 34 comprises an extension button 36 and a retraction button 38. Specifically, the extension 36 and retraction 38 buttons are 25 arrow-shaped, or triangular-shaped, to further aid the user in understanding the functions of the buttons. The arrow-shape or a point of the triangle follows the direction of the movement of the charging cable 42. The extension button 36 extends the charging cable 42 from a cable store (52, Figure 5) and the retraction button 38 retracts the charging cable 42 into the cable store 52. 30 In the current embodiment, the buttons 36, 38 are momentary switches connected to the controller 35. The controller 35 interprets the operation of the momentary switches 02 06 25 and produces a signal (56, Figure 6) which, in the current embodiment, is transmitted through a wired connection with the electric vehicle charger 44. An indicator light 40 is positioned between the extension button 36 and the retraction button 38. The position of the indicator light 40 ensures that it is visible to the user 5 especially when controlling the movement of the charging cable 42. This is so that the user can always see the status of the movement of the charging cable, the electric vehicle charger and / or the status of the charge of the electric vehicle. Referring to Figure 2, another embodiment of a plug for an electric vehicle charging cable is generally indicated in 10’. The different embodiments share the same or 10 similar features; therefore, reference numerals will be maintained for the same or similar features. In the embodiment shown in Figure 2, the control input means 34 provided in the main body element 18 is a single axis joystick 37. A stick 39 of the single axis joystick 37 can be moved between a first position, a second 15 position and a stop position. The stick is connected to and extends from a rotating body which rotates about an axis passing through the plug 10’. The axis extends perpendicularly to the direction of travel of the stick. The stop position is the central or rest position of the stick 39. For the first position, the stick 39 is moved towards the connector end element 14 for extending the charging 20 cable 42. For the second position, the stick 39 is moved towards the cable end element 16 for retracting the charging cable back to the electric vehicle charger 44. The single axis joystick 37 is biased towards the stop position. Therefore, when a user accidentally drops the plug 10’, the stick 39 of the single axis joystick 37 goes back to the stop position which stops the movement of the charging cable 42. Put another way, 25 the biasing functions as the operator presence control means. The travel of the single axis joystick 37 from the stop position to a first position or a second position can be interpreted to provide a desired extension or retraction speed of the charging cable 42. The further the stick 39 of the single axis joystick 37 is moved towards the connector end element 14 or the cable end element 16 of the plug 10’, the 30 higher the desired rotational motor speed. For example, if the stick 39 is only moved slightly towards the connector end element 14 in the first position, the extension of the 02 06 25 charging cable 42 is slow. On the other hand, if the stick 39 is moved more towards the connector end element 14, the extension of the charging cable 42 is faster. Referring to Figures 3 to 6, an electric vehicle charger is generally indicated at 44. The electric vehicle charger includes the plug according to the first embodiment shown in 5 Figure 1, therefore, reference numerals will be maintained. However, the plug according to the second embodiment may also be used. The plug 10 connected to a charging cable 42. A portion of the charging cable 42 is wound around a charging cable store 52 disposed underground. In this embodiment, the electric vehicle charger 44 is an overground bollard. However, other electric vehicle 10 chargers can be underground chargers that extend overground when in use, moreover, the charging cable store 52 may be disposed above ground. The electric vehicle charger 44 shown in Figure 3 shows the plug 10 when it is not in use, i.e., the cable 42 in the fully retracted position. The plug 10 rests vertically within an aperture 46 in the electric vehicle charger 44. 15 When in use, the plug 10 is pulled out of the electric vehicle charger 44 as shown in Figure 4. An arrow 48 shows the direction of the movement of the charging cable 42 when it is extending from the electric vehicle charger 44. An arrow 50 shows the direction of the charging cable 42 when it is retracting back into the electric vehicle charger 44. 20 Referring to Figure 5, a cut-out view of the electric vehicle charger 44 is shown. The charging cable 42 extends between the plug 10 and a charging cable store 52 disposed underground for storing a portion of the charging cable. The cable store 52 is connected to a charging cable store motor (58, Figure 6). A motor control may be provided in the electric vehicle charger 44 for controlling the motor 58. 25 When the user operates the control input means 34, a controller disposed inside the plug 10 interprets the operation and sends a signal 56 which controls operation of the cable store motor 58. The signal may be sent through wires in the charging cable or wirelessly. For example, the controller interprets operation of the extension button 36 and sends a signal to the electric vehicle charger 44 which causes the motor 58 to 30 rotate in a direction necessary to unwind the charging cable 42 from the cable store 52. When the user presses the retraction button 38, the controller interprets the operation and sends a signal 56 which causes the motor 58 to rotate the opposite way to retract the charging cable 42 back into the cable store 52. The embodiments described above are provided by way of example only, and various changes and modifications will be apparent to persons skilled in the art without departing from the scope of the present invention as defined by the appended claims. 02 06 25

Claims

02 06 251. An electric vehicle charging plug for controlling a motorised charging cable dispensing and retracting apparatus, the plug comprising:a handheld plug body comprising a connector end for connecting to a5 charging socket of an electric vehicle and a cable end; anda control input means disposed on or in the handheld plug body and connected to a controller for remotely controlling the motorised charging cable dispensing and retracting apparatus, wherein the controller is adapted to interpret the operation of the control input means and generate a signal for10 extending or retracting a charging cable using a motor of the motorisedcharging cable dispensing and retracting apparatus, in which the controller is adapted to control the speed of the motorised charging cable dispensing and retracting apparatus based on the operation of the control input means, and in which the extent of travel of the control input means is interpreted as a desired15 motor speed by the controller.

2. An electric vehicle charging plug as claimed in claim 1, in which the control input means comprises a single axis joystick.

3. An electric vehicle charging plug as claimed in claim 2, in which the single axis joystick comprises a first position and a second position, wherein in the first20 position the controller is adapted to cause the motor to dispense the chargingcable and wherein in the second position the controller is adapted to cause the motor to retract the charging cable.

4. An electric vehicle charging plug as claimed in claim 1, in which the control input means comprises a tilt sensor.25 5. An electric vehicle charging plug as claimed in any preceding claim, in whichthe control input means is disposed on a section of the handheld plug body towards the connector end.

6. An electric vehicle charging plug as claimed in any preceding claim, further comprising a wireless communication means for communicating the signal30 wirelessly to the motor.02 06 257. An electric vehicle charging plug as claimed in any of claims 1 to 5, further comprising a wired communication means for communicating the signal through a wired connection with the motor.

8. An electric vehicle charging plug as claimed in any preceding claim, further 5 comprising a display for displaying information to the operator.

9. An electric vehicle charging plug as claimed in claim 8, in which the display is provided on or in the plug body.

10. An electric vehicle charging plug as claimed in any preceding claim, further comprising a speaker provided on or in the plug body.10 11. An electric vehicle charging plug as claimed in any preceding claim, in which ahandle portion is provided in the handheld plug body towards the charging end, wherein the handle portion has a reduced diameter compared to the rest of the plug body.

12. An electric vehicle charging plug as claimed in any preceding claim, in which 15 the handle includes a grip for assisting the operator in gripping the plug and forproviding a soft surface.

13. An electric vehicle charging cable dispensing and retracting system comprising an electric vehicle charging plug as claimed in any preceding claim disposed at one end of an electric vehicle charging cable and a motorised charging cable 20 dispensing and retracting apparatus, the apparatus comprising:a charging cable store for storing the charging cable; andan electric motor for extending or retracting the electric vehicle charging cable to or from the store.

14. An electric vehicle charging cable dispensing and retracting system as claimed 25 in claim 13, in which the charging cable store is a charging cable drum ontowhich the charging cable is wound.

15. A method for dispensing or retracting an electric vehicle charging cable, the steps comprising:taking a plug as claimed in any of claims 1 to 12 from its position on an 30 electric vehicle charger;operating a control input means to extend a charging cable away from a charging cable store;plugging a connector end of the plug into a charging socket for charging an electric vehicle;5 unplugging the connector end of the plug from the charging socket aftercharging the electric vehicle;operating the control input means on the plug to retract the charging cable towards the electric vehicle charger; andplacing the plug back to its position on the electric vehicle charger.02 06 25

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