Rapid charging system and method for forming an electrically conductive connection

Abstract

The invention relates to a rapid charging system and to a method for forming an electrically conductive connection between an electrically driven vehicle, in particular an electric bus or the like, and a stationary charging station, comprising a positioning unit with a contact device and a positioning device and comprising a charging contact device. The charging contact device can be located on the vehicle, and the positioning unit can be located on the stationary charging station or vice versa. A contact element (28) of the contact device can be moved relative to a charging contact element of the charging contact device by means of the positioning unit and can be brought into contact with the charging contact element. The contact element can be positioned, by means of the positioning device, between a contact position for transmitting a current and a retracted position for interrupting the current. The contact element and / or the charging contact element is in the form of a hollow profiled part, preferably an elongated hollow profiled part, having an at least partly round cross-sectional shape.

Description

[0001] Fast charging system and method for forming an electrically conductive connection

[0002] The invention relates to a fast charging system and a method for forming an electrically conductive connection between an electrically powered vehicle, in particular an electric bus or the like, and a stationary charging station, by means of a fast charging system comprising a positioning unit with a contact device and a positioning device, and a charging contact device, wherein the charging contact device can be arranged on the vehicle and the positioning unit on the stationary charging station or vice versa, wherein a contact element of the contact device can be moved relative to a charging contact element of the charging contact device and can be contacted by means of the positioning unit, wherein the contact element can be positioned between a contact position for current transmission and an insertion position for current interruption by means of the positioning device.

[0003] Such a fast-charging system and method is known from the prior art and is regularly used in electrically powered vehicles. These vehicles can be electric buses, but also, in principle, other vehicles such as trains, trams, or ferries that are not permanently connected to an overhead line or similar infrastructure. In these vehicles, the electrical energy storage system is recharged during a break at a stop or depot by a stationary charging station. The vehicle is electrically connected to the stationary charging station at the depot, and the vehicle's energy storage system is charged, for example, overnight.

[0004] To establish an electrically conductive connection between the vehicle and the stationary charging station, a contact device of a positioning unit of the fast-charging system is used. The positioning unit is typically mounted above the vehicle at a parking space in the vehicle depot or at a bus stop. A contact element of the contact device is then moved by a positioning device of the positioning unit towards a charging contact element of a charging contact device of the fast-charging system, which is typically located on the roof of the vehicle, thus establishing an electrical connection. For example, a contact device can have at least four contact elements, with two contact elements typically serving for energy transmission, one contact element as a grounding conductor, and another contact element for data transmission.Grounding can be achieved and implemented via a pantograph frame of the positioning unit. A typical rapid charging system is known, for example, from WO 2018 / 130618 Al.

[0005] In the prior art of fast-charging systems, the contact element is typically designed as a relatively flat solid profile, especially made of copper, with a rectangular cross-sectional shape. The contact element is usually in the form of a contact rail. In principle, an electric current flowing through a conductor generates heat, which can lead to damage, particularly to the conductor itself or at contact interfaces. For this reason, it is always essential to ensure that the current transmitted through a conductor is compatible with the conductor's current-carrying capacity. Current-carrying capacity refers to the maximum permissible current that a conductor can carry continuously under specified conditions without exceeding a certain permissible temperature. The current-carrying capacity of a conductor depends on its material and geometry.

[0006] To limit the heat generated in the contact element as a result of the transfer of a charging current, the contact element known from the prior art is comparatively tall or wide. Therefore, the material consumption for the contact element, and consequently the manufacturing costs and weight of the contact element, are comparatively high. Reducing material consumption is desirable.

[0007] Furthermore, it is desirable to increase the current-carrying capacity of the contact element to transmit a higher charging current. Increasing the charging current can reduce charging time.

[0008] Another disadvantage of using the contact element, which is designed as a relatively flat solid profile with a rectangular cross-section, is that because the contact surface formed by the contact element, intended for contacting a charging contact surface formed by the charging contact element, is flat, angular tolerances of the vehicle below the positioning unit can lead to a reduction in contact quality. As a result, the charging current is reduced, at least temporarily, and the charging time is increased. Similarly, the charging contact element, which can be geometrically similar to the contact element, can also suffer from the same disadvantages.

[0009] The present invention therefore aims to propose a fast charging system and a method that is cost-effective or feasible and enables a reduction in charging time.

[0010] This problem is solved by a fast charging system having the features of claim 1 and a method having the features of claim 12.

[0011] The fast charging system according to the invention for an electrically powered vehicle, in particular an electric bus or the like, for forming an electrically conductive connection between the vehicle and a stationary charging station comprises a positioning unit with a contact device and a charging contact device, wherein the charging contact device is arrangable on the vehicle and the positioning unit on the stationary charging station or vice versa, wherein a contact element of the contact device is movable relative to a charging contact element of the charging contact device and can be contacted with it by means of the positioning unit, wherein the contact element can be positioned between a contact position for current transmission and a retraction position for current interruption by means of the positioning device, wherein the contact element and / or the charging contact element is a, preferably elongated,The hollow profile has a cross-sectional shape that is at least partially round.

[0012] According to the invention, the fast charging system comprises a positioning unit and a charging contact device, the positioning unit itself comprising a contact device and a positioning device. The charging contact device can be arranged on the vehicle and the positioning unit on the stationary charging station, or vice versa. By means of the positioning unit, a contact element of the contact device is movable relative to and can be made to contact a charging contact element of the charging contact device, and the contact element can be positioned between a contact position for current transmission and a retraction position for current interruption by means of the positioning device.

[0013] The contact device can have at least one contact element or a plurality of contact elements, and the charging contact device can have at least one charging contact element or a plurality of charging contact elements. Each charging contact element can be contacted by at least one, preferably exactly one, contact element.

[0014] The positioning unit can be arranged at a stationary charging station for an electrically powered vehicle and serves to move the contact element(s) of the contact device onto the charging contact element(s) of the charging contact device, wherein the charging contact device can be arranged on the vehicle, in particular on a vehicle roof, and to make electrical contact with it(s). This makes it possible to supply the vehicle with electrical energy during a break in travel at a stop or vehicle depot and to store this energy in the vehicle. The movement of the contact element(s) onto the charging contact element(s) is achieved by...The charging contact elements are integrated with the positioning unit, which can be mounted above the vehicle, for example, on a mast, underpass, support structure, or ceiling structure of a hall or roof. The contact element(s) can be positioned at the lower end of the positioning unit and moved from an upper insertion position to a lower contact position for current transmission or contacting the charging contact element(s). This movement of the contact element(s) is accomplished by the positioning device. A defined contact force can be applied to the contact element(s) in the contact position. The contact element(s) can be stored in the insertion position when the fast charging system is not in use.Alternatively, the positioning unit can also be arranged on the vehicle, particularly on the vehicle roof, with the charging contact device being located above the vehicle, for example on a mast, underpass, support structure, or ceiling structure of a hall or roof structure. In this case, the contact element(s) can then be moved from a lower insertion position to an upper contact position for current transmission or contacting the charging contact element(s).

[0015] According to the invention, the contact element and / or the charging contact element is designed as a hollow profile, preferably elongated, with a cross-sectional shape that is at least partially round. By designing the contact element and / or the charging contact element as a hollow profile, the material from which the contact element or charging contact element is formed can be reduced, thus saving on manufacturing costs and weight. Furthermore, the surface area of ​​the contact element and / or charging contact element can be increased to enhance its current-carrying capacity, thereby increasing the charging current and consequently reducing the charging time.It has been found that the current-carrying capacity of the contact element and / or the charging contact element can be increased by enlarging the surface area of ​​the contact element and / or the charging contact element, since the heat generated by the current flow can be dissipated more effectively due to the increased surface area. Furthermore, the at least partially round cross-sectional shape of the contact element and / or the charging contact element provided according to the invention allows at least one contact surface formed by the contact element and / or at least one charging contact surface formed by the charging contact element to be curved. Thus, the surface of the contact element and / or charging contact element can be curved at least in certain areas, namely at least in one region of the contact surface or charging contact surface. In areas away from the contact surface or charging contact surface, the surface can, in principle, also be flat.The curvature enables improved contact between the contact element and the charging contact element in the case of angular tolerances, especially of the electrically powered vehicle equipped with the charging contact device below the stationary charging station equipped with the positioning unit, and thus an improved formation of a conductive connection between the electrically powered vehicle and the stationary charging station, so that in the case of angular tolerances no adverse effects on the charging current and the charging time can develop.

[0016] The cross-sectional shape of the contact element and / or the charging contact element can be round. The surface of the contact element and / or the charging contact element can then be curved throughout. Preferably, the cross-section of the contact element and / or the charging contact element can be circular. An elliptical cross-section of the contact element and / or the charging contact element is also conceivable.

[0017] Both the contact element and the charging contact element can be designed as a hollow profile with a cross-sectional shape that is at least partially round. Alternatively, only the contact element or only the charging contact element can be designed as a hollow profile with a cross-sectional shape that is at least partially round, while the charging contact element or contact element can be designed differently, in particular with a substantially angular cross-sectional shape, for example in the form of a contact rail, a contact strip, or a contact strip.

[0018] Advantageously, the hollow profile can be an open hollow profile. This means the hollow profile can have at least one opening connecting a cavity within the profile to its surroundings. This allows for even better heat dissipation from the hollow profile. If the hollow profile is elongated, it can be open at at least one end.

[0019] Advantageously, the hollow profile can be a tube. The contact element and / or the charging contact element can then be designed in the form of a contact tube. A tube is an open hollow profile, open at both ends. Ambient air can then flow through the hollow body, allowing heat to be dissipated even more effectively.

[0020] Advantageously, the hollow profile can be made of copper. Copper has good electrical conductivity. Alternatively, the hollow profile can be made of aluminum. Since aluminum, especially compared to copper, has a significantly lower density, it is possible to design the contact element and / or the charging contact element with a comparatively larger surface area while maintaining the same weight. This allows a comparatively higher charging current to be transmitted via the contact element and / or the charging contact element for the same weight, thus further reducing charging time. Advantageously, the positioning device can include an articulated arm assembly and a drive unit for driving the articulated arm assembly. This makes it possible to guide the contact element along a predetermined path from the entry position to the contact position and back again.

[0021] Advantageously, the articulated arm device can be designed as a single-arm system, as a scissor system (preferably with a parallelogram guide), or as a pantograph. This allows the articulated arm device to enable parallel movement of the contact element from the insertion position to the contact position.

[0022] Advantageously, the drive unit can include an adjustment drive for generating an adjustment force acting on the articulated arm assembly and a spring arrangement that mechanically interacts with the adjustment drive. The adjustment drive can be pneumatic, hydraulic, or electric. The electric drive can include an electric motor.

[0023] Advantageously, the contact device can have at least two contact element carriers, each with at least two contact elements arranged on them. Two contact elements can serve for energy transmission, one contact element can serve as a grounding conductor, and another contact element can serve for data transmission. This is particularly advantageous if the electrically powered vehicle is an electric bus. However, it is also possible for four contact elements to serve for energy transmission. This is particularly advantageous if the electrically powered vehicle is a rail vehicle. Grounding can be achieved via the wheels of the rail vehicle and a rail on which the rail vehicle is mounted, so that four contact elements can serve as power contacts. In this case, two contact elements can be provided as the negative terminal and two as the positive terminal.

[0024] Advantageously, the contact elements can be connected to each other via a parallel linkage of the contact device with two parallel connecting rods and two parallel support rods, wherein the support rods are each connected to the connecting rods in one of two parallel planes of movement via spaced-apart connecting joints and can form a parallelogram with the connecting rods. With such a positioning unit, at least four contact elements can be moved onto a charging contact element and electrically contacted with each of them. Furthermore, it is possible to distribute or apply the contact force evenly to the respective contact elements. The contact device can be arranged at a lower end of the positioning device such that the contact device is held essentially centrally or at a center of gravity.The parallel linkage can be formed from comparatively long connecting rods and short support rods, which are arranged vertically and can be connected to the connecting rods via the connecting joints.

[0025] Advantageously, the connecting rods can be connected to a base support of the contact device in a support plane parallel and centered to the planes of motion via two spaced-apart support joints, wherein the contact element supports can each be connected to the support rod via a pivot joint, the pivot joints being arranged orthogonally relative to the connecting joints, and the contact element supports each holding the contact elements coaxially relative to the axis of rotation. The connecting rods can thus be inclined relative to a horizontal plane, with the support rods always being arranged vertically within the two parallel planes of motion.Since the connecting joints can be arranged coaxially with the support joints, a uniform force distribution is always achieved, with the contact force exerted centrally on the contact device being transferred to the two support rods regardless of any inclination of the connecting rods. Furthermore, due to the symmetrical design of the contact device, its center of gravity can be positioned almost centrally, resulting in a uniform distribution of the contact force across the contact elements.

[0026] Advantageously, the contact elements can each be arranged parallel to each other on the contact element carriers, and the contact element carriers can also be arranged parallel to each other. In particular, the parallel arrangement ensures that the contact force is always distributed evenly across the contact elements. The contact elements can be easily connected to the charging contact elements on the roof of a vehicle. Preferably, the charging contact elements can run transversely, and especially orthogonally, relative to the contact elements. Even if a vehicle stops at a charging station in such a way that the contact elements come into contact with the charging contact elements on the vehicle off-center, relative to their length, the contact force can be distributed evenly.

[0027] Advantageously, the fast charging system can include a mounting frame for attaching the positioning unit to the stationary charging station or the vehicle. In particular, the mounting frame for attaching the positioning unit to the stationary charging station can be designed above the vehicle. The mounting frame can be designed for easy attachment to a pole or ceiling structure of a building.

[0028] In the inventive method for forming an electrically conductive connection between an electrically powered vehicle, in particular an electric bus or the like, and a stationary charging station by means of a fast charging system, comprising a positioning unit with a contact device and a charging contact device, wherein the charging contact device is arranged on the vehicle and the positioning unit on the stationary charging station or vice versa, wherein a contact element of the contact device is moved relative to a charging contact element of the charging contact device by means of the positioning unit and is contacted with it, wherein the contact element is positioned between a contact position for current transmission and a retraction position for current interruption by means of the positioning device, wherein the contact element and / or the charging contact element is a, preferably elongated,The hollow profile has a cross-sectional shape that is at least partially round.

[0029] For the advantageous effects of the method according to the invention, reference is made to the description of advantages of the fast charging system according to the invention.

[0030] Further advantageous embodiments of the method result from the feature descriptions of the dependent claims relating back to device claim 1.

[0031] A preferred embodiment of the invention is explained in more detail below with reference to the accompanying drawings.

[0032] Fig. 1 Perspective partial view of a fast charging system;

[0033] Fig. 2 shows a schematic sectional view of a contact element.

[0034] Figure 1 shows a perspective partial view of a fast-charging system, as is generally known from the prior art. Specifically, a positioning unit 10 of the fast-charging system is shown. The positioning unit 10, which can be arranged above an electric vehicle (not shown), allows four contact elements 11 of a contact device 12 of the positioning unit 10 to be moved relative to charging contact elements of a charging contact device of the fast-charging system (not shown), which can be arranged on the roof of the vehicle (not shown), and to be contacted with them. The positioning unit 10 comprises a positioning device 13 with an articulated arm assembly 14 and a drive unit 15 for driving the articulated arm assembly 14. The contact elements 11 are positioned by means of the positioning device 13 between a retracted position or rest position for storing the contact elements 11 and a contact position for current transmission.In Fig. 1, the contact elements 1 1 are in the contact position.

[0035] The contact device 12 has two contact element carriers 16, each with two contact elements 11 arranged thereon, wherein the contact elements 11 are connected to each other via a parallel linkage 17 of the contact device 12 to two parallel connecting rods 18 and to two parallel support rods 19, wherein the support rods 19 are each connected to the connecting rods 18 in one of two parallel planes of motion 20 via spaced-apart connecting joints 21 and form a parallelogram 22 with the connecting rods 18, wherein the connecting rods 18 are connected to a base carrier 25 of the contact device 12 in a support plane 23 running parallel and concentric to the planes of motion 20 via two spaced-apart support joints 24, wherein the contact element carriers 16 are each connected to the support rod 19 via a pivot joint 26.wherein the rotary joints 26 are arranged orthogonally relative to the connecting joints 21, wherein the contact element carriers 16 each hold the contact elements 11 coaxially relative to the axis of rotation, wherein the contact elements 11 each are arranged parallel to each other on the contact element carriers 16, and wherein the contact element carriers 16 are arranged parallel to each other. Furthermore, the fast-charging system has a mounting frame 27 for attaching the positioning unit 10 to a stationary charging station (not shown here).

[0036] The contact elements 1 1 are designed as a solid profile with an essentially angular cross-sectional shape.

[0037] Fig. 2 schematically shows a cross-sectional view of a contact element 28, which is designed as a hollow profile with a circular cross-section. Specifically, the contact element 28 is designed as a contact tube. One embodiment of a positioning unit of the fast-charging system according to the invention can be obtained by a combination of the items shown in Figs. 1 and 2, wherein, in the positioning unit 10, the contact elements 11j are each replaced by a contact element 28. In this respect, Fig. 1, with the exception of the contact elements 11j, also serves to illustrate one embodiment of the invention.

Claims

Patent claims 1. Fast charging system for an electrically powered vehicle, in particular an electric bus or the like, for forming an electrically conductive connection between the vehicle and a stationary charging station, comprising a positioning unit (10) with a contact device (12) and a positioning device (13), and a charging contact device, wherein the charging contact device can be arranged on the vehicle and the positioning unit on the stationary charging station or vice versa, wherein a contact element (28) of the contact device is movable relative to and contactable with a charging contact element of the charging contact device by means of the positioning unit, wherein the contact element can be positioned between a contact position for current transmission and a retraction position for current interruption by means of the positioning device, characterized in that the contact element and / or the charging contact element is a, preferably elongated,The hollow profile has a cross-sectional shape that is at least partially round.

2. Fast charging system according to claim 1, characterized in that the hollow profile is an open hollow profile.

3. Fast charging system according to claim 1 or 2, characterized in that the hollow profile is a tube.

4. Fast charging system according to one of the preceding claims, characterized in that the hollow profile is made of copper or aluminium.

5. Fast charging system according to one of the preceding claims, characterized in that the positioning device (13) has an articulated arm device (14) and a drive device (15) for driving the articulated arm device.

6. Fast charging system according to claim 5, characterized in that the articulated arm device (14) is designed as a single-arm system or as a scissor system, preferably with a parallelogram guide, or as a pantograph.

7. Fast charging system according to claim 5 or 6, characterized in that the drive device (15) has an adjustment drive for generating an adjustment force acting on the articulated arm device (14) and a spring arrangement mechanically cooperating with the adjustment drive.

8. Fast charging system according to one of the preceding claims, characterized in that the contact device (12) has at least two contact element carriers (16) each with at least two contact elements (28) arranged thereon.

9. Fast charging system according to claim 8, characterized in that the contact elements (28) are connected to each other via a parallel linkage (17) of the contact device (12) with two parallel connecting rods (18) and with two parallel support rods (19), wherein the support rods are each connected to the connecting rods in one of two parallel planes of movement (20) via connecting joints (21) spaced apart from each other and form a parallelogram (22) with the connecting rods.

10. Fast charging system according to claim 9, characterized in that the contact elements (28) are arranged parallel to each other on the contact element carriers (16), wherein the contact element carriers are arranged parallel to each other.

11. Fast charging system according to one of the preceding claims, characterized in that the fast charging system has a mounting frame (27) for attaching the positioning unit (10) to the stationary charging station or the vehicle.

12. Method for forming an electrically conductive connection between an electrically powered vehicle, in particular an electric bus or the like, and a stationary charging station with- a fast charging system comprising a positioning unit (10) with a contact device (12) and a positioning device (13), and a charging contact device, wherein the charging contact device is arranged on the vehicle and the positioning unit is arranged on the stationary charging station or vice versa, wherein a contact element (28) of the contact device is moved relative to a charging contact element of the charging contact device by means of the positioning unit and is contacted with it, wherein the contact element is positioned between a contact position for current transmission and an insertion position for current interruption by means of the positioning device, characterized in that the contact element and / or the charging contact element is designed as a, preferably elongated, hollow profile with an at least partially round cross-sectional shape.

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