Method for arranging a charging cable so as to engage with a vehicle charging system and a charging adapter

Abstract

A vehicle charging adapter including a connector configured to engage with a charging port of a vehicle and a receiver coupled to the connector. The receiver includes a receiver charging surface, an indicator provided on the receiver charging surface, an inner peripheral wall extending from the receiver charging surface and defining a receiver cavity extending along an insertion axis, and one or more receiver electrical contacts provided on the inner peripheral wall within the receiver cavity. The one or more receiver electrical contacts are electrically connected to the connector.

Description

Technical Field

[0001] (Cross - Reference to Related Applications) This application claims priority to U.S. Patent Application No. 17 / 858,251, filed on July 6, 2022, the entire disclosure of which is incorporated herein by reference.

[0002] This specification generally relates to a charging system, and more specifically, to a charging system for an electric vehicle.

Background Art

[0003] A parking system can be used to automatically park a vehicle within a parking structure. The parking system can transport the vehicle to various spots within the parking structure. Further, a user may want to charge the vehicle while it is parked within the parking structure. However, it is difficult to automate vehicle charging while the vehicle is parked within the parking structure because the charging port location varies for each vehicle.

Summary of the Invention

[0004] In one embodiment, a vehicle charging adapter includes a connector configured to engage a charging port of a vehicle and a receiver coupled to the connector. The receiver includes a receiver charging surface, an indicator provided on the receiver charging surface, an inner peripheral wall extending from the receiver charging surface and defining a receiver cavity that extends along an insertion axis, and one or more receiver electrical contacts provided on the inner peripheral wall within the receiver cavity. The one or more receiver electrical contacts are electrically connected to the connector.

[0005] In another embodiment, the vehicle charging system includes a vehicle charging adapter, a plunger, and a charging cable. The adapter includes a connector configured to engage a charging port of the vehicle and a receiver coupled to the connector. The receiver includes a receiver charging surface, an indicator provided on the receiver charging surface, an inner peripheral wall extending from the receiver charging surface and defining a receiver cavity that extends along an insertion axis, and one or more receiver electrical contacts provided on the inner peripheral wall within the receiver cavity, and the one or more receiver electrical contacts are electrically connected to the connector. The plunger is an insertion member extending along the insertion axis from a plunger charging plate, the insertion member being at least partially positionable within the receiver cavity of the receiver, and the insertion member includes one or more plunger electrical contacts that mate with the one or more receiver electrical contacts when the insertion member is disposed within the receiver cavity. The charging cable transmits current to the one or more plunger electrical contacts of the plunger.

[0006] In yet another embodiment, the method includes detecting the position of an adapter extending from a charging port of a vehicle, positioning a plunger relative to the adapter such that the plunger is disposed above a receiver of the adapter along an insertion axis, and lowering the plunger along the insertion axis such that an insertion member is disposed within a receiver cavity of the receiver and one or more plunger electrical contacts of the plunger engage one or more receiver electrical contacts of the receiver. The adapter includes a receiver coupled to a connector, the receiver including a receiver charging surface, an indicator provided on the receiver charging surface, an inner peripheral wall extending from the receiver charging surface and defining a receiver cavity extending along the insertion axis, and one or more electrical contacts provided on the inner peripheral wall within the receiver cavity, the one or more electrical contacts being electrically connected to the connector. The plunger includes an insertion member extending along the insertion axis from a plunger charging plate and at least partially positionable within the receiver cavity of the receiver, one or more plunger electrical contacts that mate with one or more receiver electrical contacts when the insertion member is disposed within the receiver cavity, and a charging cable that transmits current to the one or more plunger electrical contacts.

[0007] These and additional features provided by the embodiments described herein will be more fully understood in consideration of the following detailed description in conjunction with the drawings.

Brief Description of the Drawings

[0008] The embodiments shown in the drawings are for illustrative and explanatory purposes and are not intended to limit the subject matter defined by the claims. The following detailed description of the exemplary embodiments will be understood when read in conjunction with the following drawings in which like structures are denoted by like reference numerals.

[0009]

Figure 1

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Figure 2

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Figure 3

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Figure 5

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Figure 8

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Figure 9

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Figure 10

[0019]

Figure 11

[0020] FIG. 1 schematically shows an embodiment of a vehicle charging system for charging an electric vehicle. The vehicle charging system generally includes a plunger connected to an electric vehicle charging station, a vehicle charging adapter, a gantry for operating the plunger, and a control system for controlling the vehicle charging system. The plunger is connected to a current source that supplies current to the plunger and is configured to engage the adapter and transmit current to the adapter. The adapter is configured to engage the charging port of the electric vehicle and transmit current from the plunger to the vehicle battery connected to the charging port. The control system is configured to identify the position of the adapter and operate the gantry to move the plunger into the adapter.

[0021] The vehicle charging system can be used in conjunction with an automatic parking system for automatically parking the vehicle within a parking structure. The automatic parking system can use a lift to lift the vehicle and transport it to a parking space within the parking structure. The driver can insert the adapter into the charging port of the vehicle before the vehicle is transported to the parking structure. When the vehicle is automatically parked within the parking structure by the automatic parking system, the gantry can automatically insert the plunger into the adapter to start charging the vehicle. Various embodiments of the vehicle charging system and the operation of the vehicle charging system are described in more detail herein.

[0022] As used herein, the term "longitudinal direction" refers to the front-to-rear direction of the vehicle (i.e., the + / -Y direction shown in FIG. 1). The term "lateral direction" refers to the vehicle width direction (i.e., the + / -X direction shown in FIG. 1), which is transverse to the longitudinal direction. The terms "vertical direction" or "upward" or "downward" refer to the up-and-down direction of the vehicle (i.e., the + / -Z direction shown in FIG. 1).

[0023] Referring now to FIG. 1, a vehicle charging system 100 for an electric vehicle 10 is shown. The electric vehicle 10 can include one or more wheels 12, one or more motors 14 operatively coupled to the one or more wheels 12 for driving the wheels 12, a battery 16 operatively coupled to the motors 14 for supplying current to the motors 14, and a charging port 18 operatively coupled to the battery 16 for transmitting current to the battery 16. FIG. 1 shows the electric vehicle 10 as a passenger vehicle such as a car or an SUV, but the electric vehicle 10 is contemplated to be and can be any vehicle having a battery 16 that supplies current to a motor that assists in driving the wheels 12 of the vehicle 10, such as, for example, a hybrid vehicle. The charging port 18 can be any conventional charging port for transmitting current from an electric vehicle charger or charging station 50 (FIG. 4) to the battery 16 of the electric vehicle 10. For example, the charging port 18 can be a type 1 or type 2 AC connector type charging port. Alternatively, the charging port 18 can be a DC type charging port.

[0024] The vehicle charging system 100 can include a plunger 102, an adapter 104, a gantry 106 (FIG. 4), and a control system 108 (FIG. 5). Referring now to FIGS. 1 - 3, the adapter 104 can include a connector 110 configured to engage a charging port 18 of the electric vehicle 10, a receiver 112 coupled to the connector 110, and a neck 114 extending between the receiver 112 and the connector 110. The neck 114 can include a first end 116 fixed to the connector 110 and an opposite second end 118 fixed to the receiver 112. The neck 114 can include a first portion 120 extending from the first end 116 toward the second end 118 and a second portion 122 extending from the first portion 120 to the second end 118. The second portion 122 can extend obliquely with respect to the first portion 120. The distance that the neck 114 extends can be limited such that the distance that the adapter 104 extends from the charging port 18 does not exceed the distance that the vehicle side mirror of the vehicle 10 extends in the vehicle lateral direction. In other words, the neck 114 can extend a predetermined distance such that the receiver 112 does not extend in the vehicle lateral direction beyond the vehicle side mirror when the adapter 104 is attached to the charging port 18. However, it is contemplated and possible for the adapter 104 to extend further beyond the vehicle side mirror. In an embodiment, the vehicle 10 can include a camera instead of a vehicle side mirror. In such an embodiment, the neck 114 can be sized such that the distance that the adapter 104 extends from the charging port 18 does not exceed the distance that the vehicle camera extends in the vehicle lateral direction.

[0025] The connector 110 may be a conventional charging connector for an electric vehicle 10, such as an SAE J1772 connector. The connector 110 can include a charging portion 124 configured to engage with a charging port 18 of the electric vehicle 10, and a handle 126 extending from the charging portion 124. The charging portion 124 can include a plurality of charging pins (not shown) configured to transmit current to the charging port 18 when the connector 110 is engaged with the charging port 18. The handle 126 may extend obliquely from the charging portion 124 at an angle equal to the angle at which the second portion 122 extends from the first portion 120 of the neck 114. In other words, the second portion 122 of the second portion 122 may extend on the same straight line as the charging portion 124 of the connector 110.

[0026] The receiver 112 can include a receiver charging surface 130, an opposite lower surface 132, an outer peripheral surface 134 extending around the receiver charging surface 130, an indicator 136 provided on the receiver charging surface 130, an inner peripheral wall 138, and one or more receiver electrical contacts 140. The outer peripheral surface 134 may be fixed to the second end 118 of the neck 114. The inner peripheral wall 138 can extend from the receiver charging surface 130 to the lower surface 132 and define a receiver cavity 142 that extends along the insertion axis 144. As shown in FIGS. 2 and 3, the receiver cavity 142 may extend through the entire receiver 112. However, it is contemplated and possible that the receiver cavity 142 may extend only partially through the receiver 112. The insertion axis 144 may extend perpendicularly through the receiver charging surface 130 such that the receiver charging surface 130 of the receiver 112 extends along a plane perpendicular to the insertion axis 144, and the insertion axis 144 may be circumferentially surrounded by the inner peripheral wall 138. In an embodiment, the insertion axis 144 may extend parallel to the vertical direction (e.g., + / -Z direction). However, it is contemplated and possible that the insertion axis 144 may extend obliquely with respect to the vertical direction, such as perpendicular to the vertical direction (e.g., in the longitudinal direction (e.g., + / -Y direction) or the transverse direction (e.g., + / -X direction)), or in a combination of the vertical, transverse, and / or longitudinal directions.

[0027] As shown in FIGS. 2 and 3, the receiver cavity 142 has an upper end 146 at the receiver charging surface 130 and an opposite lower end 148 at the lower surface 132, and the lower end 148 may be frustoconical in shape with a lower width extending across the receiver cavity 142 that is smaller than the upper width of the upper end 146 extending across the receiver cavity 142. However, the receiver cavity 142 is contemplated and can have any shape such as cylindrical that is capable of receiving the plunger 102.

[0028] The indicator 136 functions as a locator for specifying the position of the receiver cavity 142 relative to the indicator 136. For example, the indicator 136 may be a reference marking. The indicator 136 may be provided radially outside the diameter of the opening 150. The opening 150 extends through a receiver 112 sized and shaped to circumferentially surround the insertion shaft 144 and surround the receiver cavity 142, allowing the plunger 102 to extend through the opening 150 into the receiver cavity 142. The indicator 136 can include a ferromagnetic material disposed on the receiver charging surface 130 of the receiver 112 that indicates the position of the receiver cavity 142 of the receiver 112. In an embodiment, the indicator 136 can cover the entire receiver charging surface 130. The ferromagnetic material can engage a magnet to hold the adapter 104 in contact with the plunger 102, as described in more detail herein.

[0029] One or more receiver electrical contacts 140 may be coupled and provided to the inner peripheral wall 138 within the receiver cavity 142. Each of the receiver electrical contacts 140 may be arranged such that the receiver electrical contact 140 is ring-shaped and extends along the inner peripheral wall 138 to circumferentially surround the insertion shaft 144. In an embodiment, the receiver electrical contact 140 may be an inclined coil. However, the receiver electrical contact 140 is contemplated and can be any other conventional electrical contact that can be disposed within the receiver cavity 142 and transmit current to the charging unit 124.

[0030] One or more receiver electrical contacts 140 may be electrically connected to the charging pins of the connector 110 via a conduit that transmits current from the receiver electrical contacts 140 to the charging pins. The one or more receiver electrical contacts 140 may include a first electrical contact 152 and a second electrical contact 154. The first electrical contact 152 circumferentially surrounds the insertion shaft 144 and is spaced from the receiver charging surface 130 by a first distance, and the second electrical contact 154 circumferentially surrounds the insertion shaft 144 and is spaced from the receiver charging surface 130 by a second distance that is greater than the first distance.

[0031] In an embodiment where the receiver cavity 142 is frustoconical in shape, the first electrical contact 152 and the second electrical contact 154 may each have a radius that extends across the receiver cavity 142, and the radius of the first electrical contact 152 is greater than the radius of the second electrical contact 154. However, in other embodiments where the receiver cavity 142 is cylindrical in shape, the one or more electrical contacts can include a plurality of electrical contacts, each electrical contact having a radius, and the radius of the first electrical contact 152 is equal to the radius of the second electrical contact 154.

[0032] The plunger 102 can include a charging cable 160, an insertion member 162, one or more plunger electrical contacts 164, a positioning member 166, and a locking mechanism 168. The charging cable 160 may include a first end 170 operatively coupled to the charging station 50 and an opposite second end 172. The charging cable 160 can further include an electrical conduit (not shown) that extends from the first end 116 to the second end 118, and the first end 116 is electrically connected to the charging station 50 to receive current from the charging station 50 and transmit the current to the second end 118, specifically to the plunger electrical contacts 164.

[0033] The insertion member 162 is operably coupled to the second end 118 of the charging cable 160 to receive current from the charging station 50. The insertion member 162 can include a plunger plate 174 and an insertion protrusion 176 extending from the plunger plate 174 in a direction away from the charging cable 160. The plunger plate 174 can include a receiver facing surface 178 oriented along a plane extending perpendicular to the insertion axis 144 and a periphery 180 surrounding the receiver facing surface 178.

[0034] The insertion protrusion 176 can include a first end 182 coupled to the receiver facing surface 178 of the plunger plate 174, an opposite second end 184 spaced apart from the receiver facing surface 178, and an outer peripheral surface 186 extending between the first end 116 and the second end 118. The insertion protrusion 176 can extend from the receiver facing surface 178 of the plunger plate 174 along the insertion axis 144 defined by the receiver 112. The insertion protrusion 176 can be at least partially disposed within the receiver cavity 142 of the receiver 112. The insertion protrusion 176 can be sized and shaped such that it can be disposed within the receiver cavity 142. As shown in FIGS. 1-3, the insertion protrusion 176 is frustoconical in shape. However, the insertion protrusion 176 is contemplated and can have other shapes such as cylindrical, triangular, square, etc.

[0035] One or more plunger electrical contacts 164 may be provided on the insertion projection 176, such as being arranged along the outer peripheral surface 186. The plunger electrical contacts 164 may be spaced apart from each other along the insertion projection 176 between the first end 182 and the second end 184. The plunger electrical contacts 164 can be fitted with one or more receiver electrical contacts 140 when the insertion member 162 is disposed within the receiver cavity 142 for transmitting current to the receiver electrical contacts 140. Each of the plunger electrical contacts 164 may be arranged such that the plunger electrical contact 164 is ring-shaped and extends along the outer peripheral surface 186 to circumferentially surround the insertion projection 176. In an embodiment, the plunger electrical contact 164 may be an inclined coil. However, it is contemplated and possible that the plunger electrical contact 164 may be any other conventional electrical contact that can be arranged around the insertion projection 176 and transmit current to the receiver electrical contacts 140.

[0036] The plunger electrical contacts 164 may be electrically connected to the electrical conduit of the charging cable 160 such that current from the charging station 50 can be transmitted to the plunger electrical contacts 164. The plunger electrical contacts 164 may be formed of any material capable of transmitting current between the charging station 50 and the receiver electrical contacts 140.

[0037] The positioning member 166 can include one or more fingers 188 that extend obliquely from the periphery 180 of the plunger plate 174. The fingers 188 can extend at an angle and a distance such that when the insertion member 162 is disposed within the receiver cavity 142 of the receiver 112, the fingers 188 extend around the outer peripheral surface 134 of the receiver 112. The fingers 188 can act as a counterweight to orient the insertion protrusion 176 along the insertion axis 144 and enable the insertion protrusion 176 to be inserted into the receiver cavity 142 when the plunger 102 contacts the receiver 112. When the plunger 102 is engaged with the receiver 112, the fingers 188 may be spaced apart from the outer peripheral surface 134. The positioning member 166 can have any operable number of fingers 188, such as one, two, three, four, or more than four, for positioning the insertion member 162 relative to the receiver 112. In an embodiment, the positioning member 166 can have a single finger that extends around the entire plunger plate 174 so as to be conical in shape and extend around at least a portion of the outer peripheral surface 134. Thus, when the positioning member 166 contacts the receiver 112 as the plunger 102 descends toward the receiver 112, the positioning member 166 can operate to align the plunger 102, specifically the insertion protrusion 176, with the receiver cavity 142 of the receiver 112.

[0038] The locking mechanism 168 can engage with the receiver charging surface 130 of the receiver 112 when in the locked position to hold the plunger 102 in contact with the receiver charging surface 130. The locking mechanism 168 may include an electromagnet 190 that can magnetically attract the indicator 136 of the adapter 104 and thereby operate to hold the plunger 102 in contact with the receiver 112. However, it is contemplated and possible that the locking mechanism 168 includes a physical locking mechanism such as a bayonet lock for holding the plunger 102 in contact with the receiver 112. It should be understood that in an embodiment, instead of or in addition to the lock by the locking mechanism 168, the positioning member 166 may provide a physical lock.

[0039] The locking mechanism 168 may be provided on the receiver facing surface 178 of the plunger plate 174 so as to face the receiver charging surface 130 and the indicator 136 of the receiver 112. The locking mechanism 168 may be operable between a locked position and an unlocked position such that when the locking mechanism 168 is in the locked position, it holds the insertion member 162 within the receiver cavity 142, and when in the unlocked position, it allows the insertion member 162 to be removed from the receiver cavity 142. In the locked position, the locking mechanism 168 can be actuated to generate a magnetic force to attract the indicator 136 of the receiver 112 and thereby attract the receiver 112 to the locking mechanism 168.

[0040] The plunger 102 may be movable between a disengaged position (FIG. 2) and an engaged position (FIG. 3). Referring to FIG. 2, in the disengaged position, the insertion member 162 of the plunger 102 may be spaced apart from the receiver 112. Referring to FIG. 3, in the engaged position, the insertion member 162 is disposed within the receiver cavity 142 of the receiver 112 such that the plunger electrical contact 164 engages the receiver electrical contact 140. In the engaged position, the charging station 50 can be operated to supply current to the receiver electrical contact 140 via the plunger electrical contact 164. The current can then be transmitted to the charging port 18 of the vehicle 10 via the connector 110.

[0041] Referring to FIGS. 2-4, the gantry 106 may be operable to move the plunger 102 relative to the adapter 104 when the adapter 104 is disposed within the charging port 18 of the vehicle. The gantry 106 may extend across a plurality of parking spaces S within the parking structure so as to be operable to insert the plunger 102 into the adapter 104. The gantry 106 can include a gripper 200, a movement mechanism 202 coupled to the gripper 200, and an imaging device 204 for identifying the position of the receiver 112 of the adapter 104. The movement mechanism 202 may be operable in three-axis movement to move the gripper 200 in any of the X, Y, and Z directions. The gripper 200 is coupled and fixed to the plunger 102 and can move the plunger 102 together with the gripper 200.

[0042] The illustrated gantry 106 is a cable-driven parallel robot (CDPR), and the moving mechanism 202 includes a first motor 206, a first cable 208 operably coupled to the first motor 206 and the gripper 200, a second motor 210, a second cable 212 operably coupled to the second motor 210 and the gripper 200, a third motor 214, and a third cable 216 operably coupled to the third motor 214 and the gripper 200. The motors 206, 210, 214 and the cables 208, 212, 216 are oriented in different directions, and at least two of the motors 206, 210, 214 and each respective cable 208, 212, 216 extend in both the X and Y directions. In the illustrated gantry 106, the first motor 206 is oriented such that the first cable 208 extends in the X and Y directions, and the second motor 210 is oriented such that the second cable 212 extends in the X and Y directions. Each motor 206, 210, 214 may wind and unwind each cable 208, 212, 216 to move the gripper 200 in any of the X, Y, and Z directions. The charging cable 160 can extend slack from the charging station 50 such that the plunger 102 is operable between a plurality of vehicles within the plurality of parking spaces S. Although the illustrated gantry 106 is a CDPR, it is contemplated and possible that the gantry 106 may be any known robot or gantry 106 that can move in the X, Y, and Z directions. For example, the gantry 106 may be a Delta robot, a SCARA robot, a cobot, an industrial robot, or the like.

[0043] The imaging device 204 can identify the position of the indicator 136 on the adapter 104. Then, when the gripper 200 holds the plunger 102, the gantry 106 can move the gripper 200 to the position of the indicator 136 via the moving mechanism 202. The imaging device 204 can be any device capable of identifying the indicator 136 (FIG. 2), such as, for example, a camera. The imaging device 204 may be attached to the gripper 200 so as to move with the gripper 200.

[0044] In some embodiments, the plunger 102 can be fixed to the gripper 200 such that the gantry 106 can charge one vehicle at a time. However, it is contemplated and possible that a plurality of charging stations 50 and plungers 102 are arranged around a plurality of parking spaces S, and the gripper 200 can selectively grip one of the plungers 102 and insert the plunger 102 into the adapter 104 of each vehicle. In a further embodiment, a pair of charging stations 50 are arranged on both sides of each parking space S to charge a vehicle including a charging port 18 on either the driver's side or the passenger's side of the vehicle 10. In such an embodiment, the gantry 106 can grip the plunger 102 attached to the charging station 50 on the side where the charging port 18 of the vehicle 10 is provided and insert the plunger 102 into the adapter 104.

[0045] Referring now to FIG. 5, control system 108 can operate in conjunction with vehicle charging system 100 and any of the vehicle charging systems described herein. However, for simplicity, control system 108 is described only with reference to vehicle charging system 100. Control system 108 can include a controller 220 and a communication path 222 that communicatively couples controller 220 to first motor 206, second motor 210, third motor 214, locking mechanism 168, imaging device 204, and charging station 50. Controller 220 can include a processor 224 and a non-transitory electronic memory 226 to which various components are communicatively coupled. In some embodiments, processor 224 and non-transitory electronic memory 226 and / or other components are included within a single device. In other embodiments, processor 224 and non-transitory electronic memory 226 and / or other components may be distributed among a plurality of communicatively coupled devices. Controller 220 includes non-transitory electronic memory 226 that stores a set of machine-readable instructions. Processor 224 executes the machine-readable instructions stored in non-transitory electronic memory 226. Non-transitory electronic memory 226 can include RAM, ROM, flash memory, a hard drive, or any device capable of storing machine-readable instructions such that the machine-readable instructions can be accessed by processor 224. Thus, control system 108 described herein may be implemented in any conventional computer programming language, as a pre-programmed hardware element, or as a combination of hardware and software elements. Non-transitory electronic memory 226 may be implemented as a single memory module or as a plurality of memory modules.

[0046] Processor 224 can be any device capable of executing machine-readable instructions. For example, processor 224 may be an integrated circuit, a microchip, a computer, or any other computing device. Non-transitory electronic memory 226 and processor 224 are coupled to a communication path 222 that provides signal interconnections between various components and / or modules of the operating system. Thus, communication path 222 can couple any number of processors to communicate with each other, enabling the modules coupled to communication path 222 to operate in a distributed computing environment. Specifically, each of the modules can operate as a node capable of transmitting and / or receiving data. As used herein, the term "communicatively coupled" means that the coupled components can exchange data signals with each other, such as, for example, via an electrical signal through a conductive medium, an electromagnetic signal through air, an optical signal through an optical waveguide, etc.

[0047] As schematically shown in FIG. 5, communication path 222 communicatively couples processor 224 and non-transitory electronic memory 226 of controller 220 with a plurality of other components of control system 108. For example, control system 108 shown in FIG. 5 includes processor 224 and non-transitory electronic memory 226 communicatively coupled to a first motor 206, a second motor 210, a third motor 214, a locking mechanism 168, an imaging device 204, and a charging station 50. Controller 220 may be configured to operate each of the first motor 206, the second motor 210, and the third motor 214 to move gripper 200 in any of the X, Y, and Z directions.

[0048] The controller 220 may be configured to receive a signal from the imaging device 204 indicating the relative position of the indicator 136 with respect to the gripper 200 and operate the motor 14 to move the gripper 200 to the position with respect to the indicator 136. The controller 220 may arrange the gripper 200 such that the insertion member 162 of the plunger 102 is disposed along the insertion shaft 144, and operate the motors 206, 210, 214 to move the plunger 102 along the insertion shaft 144 toward the receiver 112 until the insertion protrusion 176 is disposed within the receiver cavity 142, i.e., at the engagement position. When the insertion protrusion 176 is disposed within the receiver cavity 142, the controller 220 may activate the locking mechanism 168 to generate a magnetic force that attracts the indicator 136 on the receiver 112 to the electromagnet 190 on the plunger 102, thereby disposing the locking mechanism 168 in the locked position and holding the insertion protrusion 176 within the receiver cavity 142. When the locking mechanism 168 is activated, the controller 220 may activate the charging station 50 to initiate the transfer of current to the vehicle battery 16 via the plunger electrical contact 164, the receiver electrical contact 140, the charging pins on the connector 110, and the charging port 18.

[0049] Referring now to FIG. 6, a flowchart of a method 250 for operating a vehicle charging system 100 is described herein and shown with respect to the components shown in FIGS. 1-5. As described above, the vehicle 10 can be parked in a parking structure using an automatic parking system that automatically parks the vehicle in the parking structure. The automatic parking system can use a lift that lifts the vehicle 10 and transports it to a parking space S within the parking structure. Before the driver exits the vehicle 10 and the automatic parking system transports the vehicle 10 to the parking space, the driver can insert the adapter 104 into the charging port 18. When the vehicle 10 is transported to the parking space, the method 250 may include, at step 252, detecting the position of the adapter 104 extending from the charging port 18 of the vehicle 10. The position can be detected by identifying the indicator 136 on the receiver 112 to identify the position of the receiver cavity 142 and moving the plunger 102 via the gantry 106 to align the insertion member 162 with the receiver cavity 142 within the receiver 112. The position of the adapter 104 can be detected using the imaging device 204 of the gantry 106 that identifies the indicator 136 on the receiver 112 and thereby identifies the position of the receiver cavity 142 of the receiver 112. The imaging device 204 may be further used to identify the side of the vehicle 10 on which the adapter 104 of the vehicle 10 is disposed, such as the driver's side or the passenger side of the vehicle 10.

[0050] In step 254, method 250 may include positioning plunger 102 relative to adapter 104 such that plunger 102 is disposed above receiver 112 of adapter 104 along insertion shaft 144. Plunger 102 may be disposed along insertion shaft 144 using the movement mechanism 202 of gantry 106. In step 256, method 250 includes lowering plunger 102 along insertion shaft 144 such that insertion protrusion 176 of insertion member 162 is disposed within receiver cavity 142 of receiver 112 and one or more plunger electrical contacts 164 of plunger 102 engage one or more receiver electrical contacts 140 of receiver 112, thereby enabling current to flow from plunger 102 through adapter 104 to vehicle battery 16.

[0051] In step 258, method 250 may include positioning lock mechanism 168 from an unlocked position to a locked position to hold insertion member 162 in contact with receiver 112. In the locked position, electromagnet 190 disposed on receiver facing surface 178 engages magnetically with receiver charging surface 130 of receiver 112 to hold insertion member 162 in contact with receiver 112. In step 260, method 250 may further include supplying current from charging cable 160 through plunger electrical contacts 164 to receiver electrical contacts 140. The current can flow from charging station 50 through charging cable 160, through the contact between plunger electrical contacts 164 and receiver electrical contacts 140, and to adapter 104. When the current is supplied to adapter 104, the current can flow through the connection with connector 110 to charging port 18 to charge vehicle battery 16.

[0052] When the vehicle battery 16 is fully charged at a desired charge level or the automatic parking system starts the process of moving the vehicle 10, the vehicle charging system 100 can perform the above steps in reverse order to remove the plunger 102 from the adapter 104. In particular, the method 250 may include stopping the supply of current and operating the locking mechanism 168 from the locked position to the unlocked position. The method 250 may further include moving the plunger 102 away from the receiver 112 along the insertion shaft 144 such that the insertion protrusion 176 is separated from the receiver cavity 142. When the plunger 102 is removed from the receiver cavity 142, the plunger 102 may be moved away from the adapter 104 and the vehicle 10 may be moved by the automatic parking system.

[0053] Referring now to FIGS. 7-9, an alternative vehicle charging system 300 is illustrated. It should be understood that the alternative vehicle charging system 300 is similar to the vehicle charging system 100 except for the features described herein. Accordingly, similar features use the same reference numbers starting with "3" for the reference numbers. Therefore, for the sake of brevity, these features will not be described again.

[0054] The vehicle charging system 300 can include an alternative plunger 302 and an alternative adapter 304. The alternative plunger 302 can include a charging cable 360, a plunger plate 374, and one or more biasing members 305 extending between the charging cable 360 and the plunger plate 374. The plunger plate 374 can include a cable facing surface 375, a receiver facing surface 378, and an insertion member 362 extending from the receiver facing surface 378. The cable facing surface 375 may face the charging cable 360 and may be disposed on the opposite side of the receiver facing surface 378. The plunger plate 374 may be convex at the cable facing surface 375 such that the cable facing surface 375 is curved. The plunger plate 374 can define a pair of cavities 377 extending into the plunger plate 374 from the cable facing surface 375 toward the receiver facing surface 378.

[0055] The insertion member 362 can include an extension portion 363 and an insertion end portion 365 spaced apart from the receiver facing surface 378 by the extension portion 363 coupled between the insertion end portion 365 and the receiver facing surface 378. The insertion end portion 365 can be sized and shaped to be disposed within the receiver cavity 342 of the adapter 304. As shown in FIGS. 7-9, the insertion end portion 365 may be spherical. However, the insertion end portion 365 is contemplated and can include any shape that can be disposed within the receiver cavity 342, such as, for example, a cube.

[0056] As shown in FIG. 8, the plunger plate 374 can define a pair of channels 367 that are formed within the receiver facing surface 378 and extend into the plunger plate 374 and can receive one or more plunger electrical contacts 364. The pair of channels 367 may circumferentially surround the insertion member 362, with one of the pair of channels 367 circumferentially surrounding the other of the pair of channels 367, and each of the pair of channels 367 can be sized and positioned such that they are concentrically arranged. One or more plunger electrical contacts 364 of the plunger 302 may be disposed on the receiver facing surface 378 within the pair of channels 367.

[0057] Referring again to FIGS. 7-9, the charging cable 360 can include a pair of charging wires 361 that extend from the terminal end face 359 of the charging cable 360. The charging cable 360 may be concave at the terminal end face 359 such that the terminal end face 359 is curved to complement the shape of the cable facing surface 375 of the plunger plate 374. The charging wires 361 are electrically coupled to the plunger electrical contacts 364 to transmit current to the plunger electrical contacts 364. The biasing member 305 may extend from the terminal end 359 of the charging cable 360 to the plunger plate 374 and may be coupled to the plunger plate 374. The biasing member 305 may at least partially extend into a pair of cavities 377 of the plunger plate 374. The pair of charging wires 361 may extend through the biasing member 305, which is the biasing member 305 disposed around the pair of charging wires 361 between the charging cable 360 and the plunger plate 374. The pair of charging wires 361 may extend to be electrically coupled to the plunger electrical contacts 364. In an embodiment, the biasing member 305 can include a pair of biasing members 305, with one of the pair of charging wires 361 extending through one of the pair of biasing members 305 and the other of the pair of charging wires 361 extending through the other of the pair of biasing members 305. The biasing member 305 is contemplated and can include any number of biasing members 305, such as one, two, three, four, or more than four.

[0058] As shown in FIG. 9, when the plunger plate 374 contacts the alternative adapter 304, the charging cable 360 can move further toward the adapter 304 to bring the end face 359 of the charging cable 360 into contact with the cable facing surface 375. The biasing member 305 may be compressed between the end face 359 and the cable facing surface 375 such that the biasing member 305 is fully disposed within the cavity 377 of the plunger plate 374.

[0059] Referring again to FIGS. 7 - 9, the alternative adapter 304 can include a receiver 312 having a receiver charging surface 330, a locking mechanism 368 (FIG. 9), and one or more receiver electrical contacts 340. The receiver 312 can define a pair of channels 331 extending within the receiver 312 that are formed within the receiver charging surface 330 and can receive the one or more receiver electrical contacts 340. The pair of channels 331 can circumferentially surround the receiver cavity 342. The one or more receiver electrical contacts 340 of the receiver 312 may be disposed on the receiver charging surface 330 within the pair of channels 331.

[0060] The one or more receiver electrical contacts 340 of the receiver 312 may be disposed on the receiver charging surface 330 of the receiver 312 such that when the insertion end 365 of the insertion member 362 is disposed within the receiver cavity 342 of the receiver 312, i.e., in the engaged position, the one or more plunger electrical contacts 364 and the one or more receiver electrical contacts 340 are in contact with each other.

[0061] The locking mechanism 368 may be disposed within the receiver cavity 342 and may be operable between a locked position and an unlocked position. The locking mechanism 368 can grip the insertion end 365 when disposed within the receiver cavity 342, and in the locked position, the locking mechanism 368 prevents the insertion end 365 from being removed from the receiver 312. The locking mechanism 368 may release the insertion end 365 to allow the insertion end 365 to be removed from the receiver 312 when the locking mechanism 368 is in the unlocked position. The locking mechanism 368 may include one or more actuators 369 operably coupled to one or more locking members 371. The locking members 371 may be disposed on both sides of the insertion end 365. When the insertion end 365 is disposed within the receiver cavity 342, the actuator 369 can be actuated to move the locking members 371 into and out of contact with the insertion end 365 of the plunger 302. In the unlocked position, the locking members 371 may be spaced apart from the insertion end 365, and in the locked position (shown by the phantom line), the locking members 371 may contact the insertion end 365 to hold the insertion end 365 within the receiver cavity 342.

[0062] Referring now to FIGS. 10 and 11, another alternative vehicle charging system 400 is illustrated. It should be understood that the alternative vehicle charging system 400 is similar to the vehicle charging system 100 except for the features described herein. Accordingly, like features are designated by the same reference numbers beginning with "4". Accordingly, for the sake of brevity, these features will not be described again.

[0063] The vehicle charging system 400 can include an alternative plunger 402 and an alternative adapter 404. The alternative plunger 402 can include a plunger plate 474 having an end face 477, a receiver facing face 478 opposite the end face 477, a flange 479, and a movable insertion member 462. The plunger plate 474 of the plunger 402 can define an opening 481 extending from the receiver facing face 478 to the end face 477. The flange 479 may partially extend radially inwardly within the opening 481 to reduce the radius of the opening 481 of the end face 477.

[0064] The insertion member 462 can include a charging portion 463 and a connection portion 465. The connection portion 465 may be connected and fixed to the charging cable 460 and may be disposed between the charging cable 460 and the charging portion 463. The thickness of the connection portion 465 may be smaller than the thickness of the charging portion 463 such that the insertion member 462 defines a contact surface 476. The thickness of the connection portion 465 may be smaller than the width of the opening 481 of the flange 479 such that the connection portion 465 can pass through the opening 481 of the flange 479. The width of the charging portion 463 may be larger than the width of the opening 481 of the flange 479 such that the contact surface 476 can contact the flange 479 to prevent the charging portion 463 from passing through the opening 481 of the flange 479.

[0065] The connection portion 465 may be connected to the charging cable 460 such that movement of the charging cable 460 moves the insertion member 462 and contact between the contact surface 476 of the insertion member 462 and the plunger 402 moves the plunger plate 474 of the plunger 402 together with the insertion member 462. The insertion member 462 may be movably disposed within the opening 481 of the plunger plate 474 such that the insertion member 462 can move relative to the plunger plate 474. The insertion member 462 may be extendable from the opening 481 of the plunger 402 and into the receiver cavity 442 of the receiver 412 when the plunger 402 is disposed along the insertion axis 444.

[0066] The insertion member 462 may be movable between a disengaged position (FIG. 10) and an engaged position (FIG. 11). As shown in FIG. 10, in the disengaged position, the insertion member 462 is disposed within the opening 481 of the plunger plate 474 of the plunger 402 so as to be spaced apart from the receiver cavity 442. As shown in FIG. 11, in the engaged position, the charging portion 463 of the insertion member 462 extends from the opening 481 of the plunger plate 474 of the plunger 402 and is disposed within the receiver cavity 442 with the plunger electrical contact 464 in contact with the receiver electrical contact 440. The insertion member 462 can move relative to the plunger plate 474 of the plunger 402 when the plunger plate 474 contacts the receiver 412 and the charging cable 460 further advances toward the plunger plate 474 to move the insertion member 462 relative to the plunger plate 474. The charging cable 460 may advance until the charging portion 463 of the insertion member 462 is disposed within the receiver cavity 442 with the plunger electrical contact 464 in contact with the receiver electrical contact 440.

[0067] In an embodiment, a stopper 482 can be provided on the charging cable 460 to prevent the charging cable 460 and the insertion member 462 from extending excessively into the receiver 412. The stopper 482 may surround the charging cable 460 in the circumferential direction and extend therefrom so as to have a width greater than the width of the receiver cavity 442 at the flange 479. The stopper 482 may be disposed on the charging cable 460 at a distance from the charging portion 463 of the insertion member 462 such that the stopper 482 contacts the end face 477 when the plunger electrical contact 464 is in contact with the receiver electrical contact 440.

[0068] In an embodiment, an actuator 484 can be provided to position the insertion member 462 between the engaged position and the disengaged position. The actuator 484 is operably coupled to the charging cable 460 and / or the insertion member 462 and can move the charging cable 460 and / or the insertion member 462 relative to the receiver 412.

[0069] Although specific embodiments have been illustrated and described herein, it should be understood that various other changes and modifications can be made without departing from the spirit and scope of the claimed subject matter. Further, while various aspects of the claimed subject matter are described herein, such aspects need not be utilized in combination. Accordingly, the appended claims are intended to encompass all such changes and modifications that are within the scope of the claimed subject matter.

Claims

1. A vehicle charging adapter, comprising: a connector configured to engage with a charging port of a vehicle; a receiver coupled to the connector, the receiver including: a receiver charging surface; an indicator provided on the receiver charging surface; an inner peripheral wall extending from the receiver charging surface and defining a receiver cavity extending along an insertion axis; one or more receiver electrical contacts provided on the inner peripheral wall within the receiver cavity and electrically connected to the connector; a receiver including the above; A vehicle charging adapter comprising the above.

2. The vehicle charging adapter according to claim 1, further comprising a neck including a first end and a second end opposite the first end, wherein the connector is fixed to the first end of the neck and the receiver is fixed to the second end of the neck.

3. The vehicle charging adapter according to claim 1, wherein the receiver charging surface of the receiver extends along a plane perpendicular to the insertion axis.

4. The one or more receiver electrical contacts include a first electrical contact and a second electrical contact. The first electrical contact surrounds the insertion axis in a circumferential direction and is spaced apart from the receiver charging surface by a first distance. The second electrical contact surrounds the insertion axis in a circumferential direction and is spaced apart from the receiver charging surface by a second distance greater than the first distance. The vehicle charging adapter according to claim 1.

5. The receiver cavity has a frustoconical shape with an upper end on the receiver charging surface and a lower end on the opposite side. The lower end has a lower width smaller than the upper width of the upper end. The first electrical contact and the second electrical contact each include an inclined coil having a radius. The radius of the inclined coil of the first electrical contact is larger than the radius of the inclined coil of the second electrical contact. The vehicle charging adapter according to claim 4.

6. The receiver cavity is cylindrical, and each of the receiver electrical contacts includes an inclined coil having a radius. The radius of the first electrical contact is equal to the radius of the second electrical contact. The vehicle charging adapter according to claim 4.

7. The vehicle charging adapter according to claim 1, wherein the indicator includes a ferromagnetic material disposed on the receiver charging surface of the receiver.

8. A vehicle charging system, comprising: a vehicle charging adapter, comprising: a connector configured to engage with a charging port of a vehicle; A receiver coupled to the connector, a receiver charging surface, an indicator provided on the receiver charging surface, an inner peripheral wall extending from the receiver charging surface and defining a receiver cavity extending along the insertion axis, one or more receiver electrical contacts electrically connected to the connector, a receiver including the above, a vehicle charging adapter including the above, a plunger, an insertion member extending from the plunger plate along the insertion axis and at least partially disposed within the receiver cavity of the receiver, one or more plunger electrical contacts that mate with the one or more receiver electrical contacts when the insertion member is disposed within the receiver cavity, a plunger including the above, a charging cable for transmitting current to the one or more plunger electrical contacts of the plunger, A vehicle charging system comprising the above.

9. The plunger further includes a positioning member, and the positioning member includes one or more fingers extending around the receiver when the insertion member is disposed within the receiver cavity of the receiver. The vehicle charging system according to claim 8.

10. The plunger further includes a locking mechanism operable between a locked position and an unlocked position. The locking mechanism holds the insertion member within the receiver cavity when in the locked position and allows the insertion member to be removed from the receiver cavity when in the unlocked position. The vehicle charging system according to claim 8.

11. The plunger plate is oriented along a plane extending perpendicular to the insertion axis. The plunger further includes an insertion protrusion extending from the plunger plate. The one or more plunger electrical contacts are provided on the insertion protrusion. The locking mechanism is provided on the receiver-facing surface of the plunger plate. The locking mechanism magnetically engages with the receiver charging surface of the receiver when in the locked position to hold the plunger plate in contact with the receiver charging surface. The vehicle charging system according to claim 10.

12. The vehicle charging system according to claim 8, wherein the plunger plate defines an opening, and the insertion member is movable relative to the plunger plate between a disengaged position and an engaged position. At the disengagement position, the insertion member is disposed within the opening of the plunger plate, At the engagement position, the insertion member is disposed within the receiver cavity, Vehicle charging system.

13. The vehicle charging system according to claim 12, The insertion member includes a charging portion and a connection portion, the connection portion is coupled to a charging cable, the insertion member defines a contact surface, The plunger plate further includes a flange that extends partially within the opening, At the disengagement position, the contact surface of the insertion member is in contact with the flange, Vehicle charging system.

14. The plunger includes a plunger plate having a receiver facing surface, the insertion member extends from the receiver facing surface and includes an insertion end spaced from the receiver facing surface, the one or more plunger electrical contacts are disposed on the receiver facing surface, the one or more receiver electrical contacts are disposed on the receiver charging surface of the receiver, and the one or more plunger electrical contacts and the one or more receiver electrical contacts are arranged to contact each other when the insertion end of the insertion member is disposed within the receiver cavity of the receiver. The vehicle charging system according to claim 8.

15. The insertion end is a sphere, the receiver includes a locking mechanism operable between a locked position and an unlocked position, the locking mechanism grips the insertion end when disposed within the receiver cavity, the locking mechanism prevents the insertion end from being removed from the receiver at the locked position, and the locking mechanism releases the insertion end and enables the insertion end to be removed from the receiver when the locking mechanism is in the unlocked position. The vehicle charging system according to claim 14.

16. The plunger further includes one or more biasing members extending between and coupled to the charging cable and the insertion member. The vehicle charging system according to claim 15.

17. A method comprising: Detecting the position of an adapter extending from a charging port of a vehicle, the adapter comprising: A connector configured to engage the charging port of the vehicle, A receiver, A receiver charging surface, An indicator provided on the receiver charging surface, An inner peripheral wall extending from the receiver charging surface, the inner peripheral wall defining a receiver cavity extending along the insertion axis, One or more receiver electrical contacts electrically connected to the connector, A receiver including, Including detecting, Disposing the plunger relative to the adapter such that the plunger is disposed above the receiver of the adapter along the insertion axis, the plunger being, An insertion member extending from a plunger plate along the insertion axis, the insertion member being at least partially disposable within the receiver cavity of the receiver, One or more plunger electrical contacts that mate with the one or more receiver electrical contacts when the insertion member is disposed within the receiver cavity, A charging cable that transmits current to the one or more plunger electrical contacts of the plunger, Including disposing, Lowering the plunger along the insertion axis such that the insertion member is disposed within the receiver cavity of the receiver and the one or more plunger electrical contacts of the plunger engage the one or more receiver electrical contacts of the receiver, A method including.

18. The method of claim 17, further comprising supplying current from the charging cable, through the plunger electrical contacts, to the receiver electrical contacts.

19. The method of claim 17, further comprising disposing a locking mechanism from an unlocked position to a locked position to hold the insertion member in contact with the receiver, the locking mechanism including an electromagnet disposed on a receiver-facing surface of the plunger plate, the electromagnet electromagnetically engaging the receiver charging surface of the receiver to hold the insertion member in contact with the receiver.

20. The disposing the plunger relative to the adapter includes identifying the indicator on the receiver and specifying the position of the receiver cavity relative to the indicator, and moving the plunger via a gantry to align the insertion member with the receiver cavity within the receiver. The method of claim 17.

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