A charger coupling device
Patent Information
- Application Number
- PCT/IN2025/051468
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2025-03-22
- Filing Date
- 2025-09-10
- Publication Date
- 2026-10-01
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Figure IN2025051468_01102026_PF_FP_ABST
Abstract
Description
TITLE OF THE INVENTION:A CHARGER COUPLING DEVICETECHNICAL FIELD
[0001] The present subject matter is related, in general to a battery pack, and more particularly, to a charger coupling device to charge a battery pack.BACKGROUND
[0002] Electric vehicles, hybrid vehicles, or other forms of electric powered vehicles typically are driven by an electric motor coupled to an electric energy reservoir such as a battery pack. The electric charge stored in the battery pack is selectively supplied to the electric motor based on vehicle propulsion requirements. The electric motor refers to an electrical device adapted to convert available electric energy to motive power. The electric motor may alternately be operable as a generator in regenerative mode operation of the vehicle, whereby the free rotation of the wheel coupled to the electric motor is converted into electrical energy, thereon the electrical energy is transmitted to the battery pack.
[0003] The battery pack or electric energy reservoir owing to the consumption of charge, required frequent charging. The charging of the battery pack may be ensued in-vehicle as well as off-vehicle. In the in-vehicle charging, the vehicle’s body panel typically accommodates a charging port which has a power line connected to the battery pack. The connection of an external charger to the charging port routes the electrical energy to the battery pack. The off-vehicle charging refers to a dockable or swappable configuration of the battery packs in the vehicle. The battery pack may be removed from the vehicle and docked in charging stations, where the same is re-charged.
[0004] In vehicles opting a dockable configuration of the battery pack, the vehicle users are obliged to locate a respective docking station or wall mounted charger for their battery to charge. In view of the preliminary state of charging infrastructure, locating an available docking station or a wall mounted charger may not always be a feasible option for the vehicle user. The limited dedicated infrastructure necessitates the requirement of alternative charging proposals for dockable battery packs, which are not as space consuming as docking stations, and provides the security of a personal space.
[0005] In a known art, portable chargers are disclosed, which are wall-mounted and bulky, limiting their usability to fixed locations like garages or charging stations, creating inconvenience for the users needing portable and flexible charging options. Further, each portable charger is operable as an adaptor, which converts the available voltage received froman external charging point to the battery voltage. The battery as well as the external charging point are connected to the portable charging device using wires. Dangling of the wires from the portable chargers creates an inconvenience in vicinity of the battery pack during the charging. Additionally, the known portable chargers fail to include features of battery data transmission to servers and personal devices.
[0006] Therefore, a need or requirement still exist in the field of portable chargers for providing a compact portable charger that solves at least the above-mentioned problems and offers enhanced accessibility, convenience, durability, performance, and reliability.
[0007] Further limitations and disadvantages of conventional and traditional approaches will become apparent to one of skill in the art, through comparison of described systems with some aspects of the present disclosure, as set forth in the remainder of the present application and with reference to the drawings.SUMMARY
[0008] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
[0009] In accordance with an embodiment illustrated herein, the present subject matter relates to a charger coupling device. The charger coupling device is configured to couple an external charger to a battery pack. The charger coupling device comprises a first connecting portion configured to detachably couple to an output connector of an external charger. The charger coupling device further comprises a second connecting portion configured to detachably couple to terminals of a battery pack. The charger coupling device further comprises a casing and a control circuit. The control circuit is enclosed in the casing. The control circuit is configured to receive one or more charger parameters from the external charger, when the charger coupling device is coupled to the external charger via the first connecting portion. The control circuit is further configured to receive one or more battery parameters from the battery pack, when the charger coupling device is coupled to the battery pack via the second connecting portion. The control circuit is further configured to regulate power, received from the external charger, to be supplied to the battery pack, when the one or more battery parameters are within a corresponding threshold range of the one or more charger parameters. The control circuit is further configured to supply the regulated power to the battery pack via the second connecting portion.
[0010] In an embodiment, the one or more battery parameters include at least a current rating, a voltage rating, a temperature rating, a power rating, a state of charge, and a state of health of the battery pack. The one or more charger parameters include at least a current rating, a voltage rating, a power rating, and a temperature rating of the external charger.
[0011] In an embodiment, the casing comprises a plurality of openings and a plurality of cover members. The plurality of openings may be configured to receive at least the first connecting portion and the second connecting portion. The plurality of cover members may be configured to selectively cover and uncover the first connecting portion and the second connecting portion.
[0012] In an embodiment, the control circuit is further configured to receive the one or more charger parameters from the external charger, when the first connecting portion is detected to be securely coupled to the external charger. The control circuit is further configured to receive the one or more battery parameters from the battery pack, when the second connecting portion is detected to be securely coupled to the battery pack. The control circuit is further configured to transmit the one or more battery parameters to an external server and a display unit.
[0013] In an embodiment, the control circuit is further configured to disable communication with the battery pack via the second connecting portion, when the one or more battery parameters exceed the corresponding threshold range of the one or more charger parameters.
[0014] In an embodiment, the control circuit is further configured to disable communication with the first connecting portion and the second connecting portion and disable the supply of the regulated power to the battery pack, when one or more operating parameters, received from the charger coupling device, the external charger, and the battery pack, are beyond a threshold range. The one or more operating parameters comprises at least one of: a state of charge of the battery pack during supply of the regulated power to the battery pack, a temperature of the battery pack and the charger coupling device during supply of the regulated power to the battery pack, a user input transmitted to the control circuit, and a current and voltage of the battery pack and external charger during supply of the regulated power to the battery pack.
[0015] In an embodiment, the control circuit further comprises at least a voltage converter and a processing unit. Further, the regulation of the power supply comprises activation of the voltage converter, by the processing unit. The voltage converter is configured to transform a voltage of the received power supply from the external charger to a voltage level required for charging the battery pack. The voltage level may be received from one of: a memory unit of the control circuit or a battery management system (BMS) of the battery pack.
[0016] In an embodiment, the control circuit further comprises a communication unit. The communication unit may be operable in one of an online mode or an offline mode. The onlinemode may be activated, when a network strength associated with a communication medium between the communication unit and the external server is beyond a pre-set threshold. The offline mode may be activated when the network strength associated with the communication medium between the communication unit and the external server is below a pre-set threshold. In an embodiment, the communication unit is configured to transmit the one or more battery parameters to a memory unit of the control circuit, when the communication unit being operable in offline mode, and retrieve the one or more battery parameters from the memory unit and transfer to the external server upon the online mode being re-instated.
[0017] In an embodiment, the charger coupling device is accommodated or installed or integrated or positioned between an overhang portion of the battery pack and a base of the battery pack. The overhang portion comprises terminals of the battery pack and the second connecting portion is configured to securely coupled to the terminals of the battery pack.
[0018] In accordance with another embodiment illustrated herein, the present subject matter relates to a control circuit for a charger coupling device. The control circuit comprises at least a communication unit, a processing unit, and a switching unit. The communication unit is configured to receive one or more charger parameters from an external charger, when the charger coupling device is securely coupled to the external charger. The communication unit is further configured to receive one or more battery parameters from a battery pack, when the charger coupling device is securely coupled to terminals of the battery pack. The communication unit is further configured to transmit at least the one or more battery parameters to an external server and a display unit. The processing unit is configured to receive the one or more battery parameters and the one or more charger parameters from the communication unit. The processing unit is further configured to regulate power, from the external charger, to be supplied to the battery pack, when the one or more battery parameters are within a corresponding threshold range of the one or more charger parameters. The switching unit is operatively coupled to the processing unit and is configured to enable supply of the regulated power to the battery pack.
[0019] In an embodiment, the communication unit being operable in one of: an online mode, when a network strength associated with a communication medium between the communication unit and the external server being beyond a pre-set threshold, or an offline mode, when the network strength associated with the communication medium between the communication unit and the external server being below the pre-set threshold. The communication unit is further configured to transmit the one or more battery parameters to a memory unit of the control circuit, when the communication unit being operable in the offlinemode. The communication unit is further configured to retrieve the one or more battery parameters from the memory unit and transfer to the external server upon the online mode being re-instated.
[0020] In an embodiment, the regulation of the power supply comprises activation of a voltage converter by the processing unit. The voltage converter is configured to transform a voltage of the received power supply from the external charger to a voltage level required for charging the battery pack. The voltage level being received from one of a memory unit of the control circuit, or a battery management system (BMS) of the battery pack.
[0021] In an embodiment, the control circuit is further configured to disable communication with the battery pack via the second connecting portion, when the one or more battery parameters exceed the corresponding threshold range of the one or more charger parameters.
[0022] In an embodiment, the control circuit is further configured to disable the supply of the regulated power to the battery pack, when one or more operating parameters, received from the charger coupling device, the external charger, and the battery pack, are beyond a threshold range. The one or more operating parameters comprise at least one of a state of charge of the battery pack during supply of regulated power to the battery pack, a temperature of the battery pack and the charger coupling device during supply of the regulated power to the battery pack, a user input transmitted to the control circuit, and a current and voltage of the battery pack and the external charger during supply of the regulated power to the battery pack.
[0023] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the disclosure, as claimed.BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The present invention will become more fully understood from the detailed description given herein below and the accompanying drawings which are given by way of illustration only and thus are not limitative of the present invention.
[0025] Figure 1 shows a block diagram illustrative of a charger coupling device along with one or more external components, in accordance with an embodiment of the present disclosure.
[0026] Figure 2(a) illustrates a perspective view of the charger coupling device coupled to a battery pack, in accordance with an embodiment of the present disclosure.
[0027] Figure 2(b) illustrates a perspective view of the battery pack, in accordance with an embodiment of the present disclosure.
[0028] Figure 3 illustrates an exploded view of the charger coupling device, in accordance with an embodiment of the present disclosure.
[0029] Figure 4(a) illustrates a top view of the charger coupling device, in accordance with an embodiment of the present disclosure.
[0030] Figure 4(b) illustrates a rear view of the charger coupling device, in accordance with an embodiment of the present disclosure.
[0031] Figure 4(c) illustrates a side view of the charger coupling device, in accordance with an embodiment of the present disclosure.
[0032] Figure 4(d) illustrates a front view of the charger coupling device engaged with the battery pack, in accordance with an embodiment of the present disclosure.
[0033] Figure 5 illustrates an exemplary flow chart of a method for charging a battery pack by using a charger coupling device, in accordance with an embodiment of the present disclosure.DETAILED DESCRIPTION OF THE DRAWINGS
[0034] The present disclosure may be best understood with reference to the detailed figures and description set forth herein. Various embodiments are discussed below with reference to the figures. However, those skilled in the art will readily appreciate that the detailed descriptions given herein with respect to the figures are simply for explanatory purposes as the system may extend beyond the described embodiments. For example, the teachings presented, and the needs of a particular application may yield multiple alternative and suitable approaches to implement the functionality of any detail described herein. Therefore, any approach may extend beyond the particular implementation choices in the following embodiments described and shown.
[0035] References to “one embodiment,” “at least one embodiment,” “an embodiment,” “one example,” “an example,” “for example,” and so on indicate that the embodiment(s) or example(s) may include a particular feature, structure, characteristic, property, element, or limitation but that not every embodiment or example necessarily includes that particular feature, structure, characteristic, property, element, or limitation. Further, repeated use of the phrase “in an embodiment” does not necessarily refer to the same embodiment.
[0036] The present invention now will be described more fully hereinafter with different embodiments. The disclosed invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather those embodiments are provided so that this disclosure will be thorough and complete, and fully convey the scope of the disclosed invention to those skilled in the art.
[0037] The present invention is illustrated with a charger coupling device. The charger coupling device is configured to engage or couple with terminals of a dockable or swappablebattery pack at one end, and an output connector of an external charger at another end. The charger coupling device receives a power input from the external charger and transmits a regulated power to the battery pack. Aspects of the present invention are applicable to any vehicle or industrial machine requiring a swappable battery pack, with the battery pack being categorised as a rechargeable electrical energy storage system (REESS). A person skilled in the art would appreciate that the disclosed subject matter is not only limited to a battery pack but is also extensible to other forms of REESS. A pre-requisite of the vehicle in accordance with the present subject matter relates to the REESS being in a swappable or dockable configuration. The dockable configuration of the REESS permits an exchange of a discharged battery pack for a fully charged one, rather than recharging the battery pack in-vehicle at a charging station.
[0038] An objective of the present subject matter is to provide a charger coupling device as a portable means for enabling charging of a battery pack.
[0039] To this end, the charger coupling device comprises a first connecting portion detachably coupled to an output connector of an external charger. A second connecting portion of the charger coupling device may detachably couple with the terminals of the battery pack. The charger coupling device comprises a control circuit which detects secure coupling of the first connecting portion and the second connecting portion with the external charger and the battery pack, respectively. Thereon, the control circuit may determine a regulated power to be supplied to the battery pack for the secured charging of the battery pack.
[0040] Another objective of the present subject matter is to ensure secure charging of the battery pack, with reduced occurrences of safety hazards.
[0041] To this end, the control circuit checks that the one or more battery parameters received from the battery pack are within a threshold of the one or more charger parameters received from the external charger, before initiating the charging of the battery pack. The disclosed feature ensures that only battery packs in compliance with the ranges of the external charger may be enabled for the charging by the charger coupling device.
[0042] It is another objective of the present subject matter to create a dossier of battery parameters for improving traceability of the battery pack coupled to the charger coupling device and for monitoring the performance of the battery pack.
[0043] In vehicles opting for in-vehicle charging infrastructure, the vehicle control unit communicating with the battery pack retains a replica of the battery parameters and their progression states. Therefore, the storage and retrieval are processed by the vehicle control unit. However, in off-vehicle charging infrastructure, public external chargers need toaccommodate an external database for retention of the battery parameters for each swappable battery. The maintenance of an external database for each battery pack requires higher processing speeds, bandwidth requirements, and continuous network connectivity. In view of addressing the drawbacks of the existing off-vehicle charging, the disclosed configuration presents the charger coupling device with the control circuit, operable in online and offline modes. Therefore, providing the storage and retrieval of the battery parameters via an external server and a display unit as per the user’s requirement.
[0044] It is another objective of the present subject matter to reduce dangling of wires otherwise prevalent in portable charging devices in order to create a tidy battery charging infrastructure.
[0045] As per a configuration of the present subject matter, the terminals of the battery pack extending from an overhang portion of the battery pack directly engages with the second connecting portion of the charger coupling device. This configuration eliminates the requirement of power cables between the battery pack and the charger coupling device, reducing power transmission as well as data transmission losses or lags.
[0046] It is another objective of the present subject matter to provide a compact and portable charger coupling device.
[0047] As per an aspect of the present subject matter, the charger coupling device is configured to be accommodated or positioned or integrated or installed into a clearance (i.e., an available space) of the battery pack extending between an overhang portion and a base of the battery pack. In other words, the dimensions of the charger coupling device is such that the charger coupling device, in an engaged configuration to the overhang portion, fits into the available space and aligns with the perimeter of the battery pack. The thickness of the charger coupling device conforms to the extension of the overhang portion. The length of the charger coupling device is between the overhang portion’s terminals and the base of the battery pack. The width of the charger coupling device is the same as the thickness of the battery pack.
[0048] The present disclosure provides the portable charger coupling device, which performs one of a battery pack charging function, a charging history inquiry function, a firmware update function, and a diagnosis function according to a connection state of the battery pack or an instruction input from a diagnostic device. Meanwhile, the embodiments are not limited to the above object, and those skilled in the art can clearly understand other objects from following description.
[0049] Figure 1 shows a block diagram illustrative of a charger coupling device 100 along with one or more external components, in accordance with an embodiment of the present disclosure.
[0050] With reference to Figure 1, 100 denotes the charger coupling device, 102 denotes a first connecting portion, 104 denotes a second connecting portion, 108 denotes a control circuit, 110 denotes a display unit, 112 denotes a battery pack, 120 denotes an external charger, 122 denotes an external server, 124 denotes one or more sensors, and 125 denotes a communication network.
[0051] For the purposes of readability of the present disclosure, the term “device” may be alternately used instead of “charger coupling device”. Further, the terms “coupled”, “engaged”, “attached”, and “connected” may be used interchangeably without limiting the scope of the desired interrelation to mechanical, electrical or data interactions.
[0052] The charger coupling device 100 is a device configured to couple the external charger 120 at one end and the battery pack 112 at another end by use of one or more connecting members such as electrical cables. The device 100 is enclosed in a casing 106 (shown in FIGS.4b and 4c). The device 100 comprises a first connecting portion 102, a second connecting portion 104, and a control circuit 108. The first connecting portion 102 and the second connecting portion 104 are communicatively coupled to the control circuit 108. The device 100 may additionally comprise one or more sensors 124 communicatively coupled to the control circuit 108.
[0053] In an aspect, the first connecting portion 102 refers to an interface or port to facilitate connection between the charger coupling device 100 and the external charger 120. The first connecting portion 102 detachably couples with an output connector or port of the external charger 120 by means of a connecting member such as electric cable. The output connector of the external charger 120 may engage or couple with the mating provisions of the first connecting portion 102. The first connecting portion 102 therefore serves as an input interface or port of power and data transmission from the external charger 120 to the device 100. The output connector of the external charger 120 may have power terminals as well as data terminals suitably coupling with the corresponding terminals of the first connecting portion 102. In a preferred embodiment, the data transmission from the external charger 120 may be achieved via one or more CAN lines. In a preferred embodiment, the communication (electrical as well as data) may be established between the device 100 and the external charger 120 via wired as well as wireless mediums.
[0054] In an aspect, the first connecting portion 102 is communicatively coupled to the control circuit 108 enclosed in the casing 106 of the device 100. The communicative coupling, in the present context, may relate to supporting of data as well as electrical transmissions. In a preferred embodiment, the first connecting portion 102 is coupled to the control circuit 108 via a wired communication network (as illustrated in Figure 3). However, wireless transmission mediums may be supported in the present configuration for the data and electrical transmission between the first connecting portion 102 and the control circuit 108.
[0055] In an aspect, the term “external charger” may refer to a commercial power source as well as a private power source. In some embodiments, the external charger 120 may be a charging station, a wall mounted charger, a home charging socket, or even a wireless charging medium. In this context, the first connecting portion 102 is suitably configured to receive and transmit the electrical and data extracted from the external charger 120 towards the control circuit 108.
[0056] In an aspect, the data transfer from the external charger 120 to the control circuit 108 may refer to the transmittal of one or more charger parameters. The one or more charger parameters may include at least a current rating, a voltage rating, a power rating, and a temperature rating of the external charger 120. Each of the current rating, voltage rating, power rating, and temperature rating may be indicative of an optimal operational range or value of the external charger 120 during charging or discharging process. The operational range may be indicative of nominal or peak values of the parameters as per default factory settings or specifications, which warrantees optimal charging or discharging performance of the external charger 120. For instance, 0-600W may be the power rating of the external charger 120, which infers that coupling of any battery pack 112 having a power rating of beyond 600W would deem the device 100 infeasible for supporting charging of the battery pack 112.
[0057] In an aspect, the power supply by the external charger 120 is of a single configuration, amenable by the device 100 to suit the power requirements of the battery pack 112 for the optimal charging.
[0058] In an aspect, the second connecting portion 104 serves as an interface or port to facilitate connection between the device 100 and the battery pack 112. The second connecting portion 104 is configured to detachably couple to terminals 112c (depicted in Figure 2(b)) of the battery pack 112. The battery pack 112, as per the present disclosure, is preferably of a dockable or swappable configuration with exposed battery terminals. The engagement of the terminals 112c of the battery pack 112 with the mating terminals of the second connectingportion 104 may permit data as well as power transfer from the second connecting portion 104 to the battery pack 112 or to a battery management system (not shown) of the battery pack 112.
[0059] The second connecting portion 104 may have a socket configuration. In a preferred embodiment, the transmittal of one or more battery parameters pertinent to the battery pack 112 may be performed by the BMS of the battery pack 112. A CAN or wired or wireless communication channel may be established between the BMS and the device 100 via the second connecting portion 104. Further, power terminals or power lines between the device 100 and the battery pack 112 via the second connecting portion 104 may permit transmittal or routing of the electric charge (i.e., supply of the electrical power) from the external charger 120 to the battery pack 112 via the first connecting portion 102 and the second connecting portion 104.
[0060] In an aspect, a wired communication between the control circuit 108 of the device 100 and the second connecting portion 104 may be provided (as depicted in Figure 3). Alternately, the control circuit 108 may be communicating via wireless communication mediums. The control circuit 108 receives the battery parameters from the BMS of the battery pack 112 and, based on processing of the received battery parameters, routes the power from the external charger 120 towards the battery pack 112. The one or more battery parameters may include at least: a current rating, a voltage rating, a temperature rating, a power rating, a state of charge, and a state of health of the battery pack 112. Each of the current rating, voltage rating, power rating temperature rating, etc. are indicative of an optimal operational range or value of the battery pack 112 during the charging process. The operational range or value may be indicative of nominal or peak values of the parameters as per default factory settings or specifications, which warrantees optimal charging performance of the battery pack 112. For instance, a voltage rating of 200V of the battery pack 112 may make a 100V external charger 120 incompatible for charging of the battery pack 112.
[0061] The control circuit 108 may refer to a printed circuit board, a multi-layer printed circuit board, a bread board coupled to multiple electronic components, a microcontroller with multiple pins, or even electrical lines connecting various electrical and electronic components such as, but not limited to, actuators and sensors of the present disclosure.
[0062] The control circuit 108 is configured to receive the one or more charger parameters form the external charger 120, when the charger coupling device 100 is coupled to the external charger 120 via the first connecting portion 102. The control circuit 108 is further configured to receive the one or more battery parameters from the battery pack 112, when the charger coupling device 100 is coupled to the battery pack 112 via the second connecting portion 104.The control circuit 108 is further configured to check the compatibility of the external charger 120 for charging the battery pack 112 based on the received charger and battery parameters. The control circuit 108 may regulate the received power, from the external charger 120, which is to be supplied to the battery pack 112, when the one or more battery parameters are within a corresponding threshold range of the one or more charger parameters. The comparison of the one or more battery parameters within the corresponding threshold range of the charger parameters adjudges the charging compatibility of the battery pack 112 vis-a-vis the external charger’s 120 configuration.
[0063] In an embodiment, the one or more charger parameters may refer to a steady state parameter of current, voltage, power, and temperature, whereas the threshold range may refer to peak values of the parameters on current, voltage, power, and temperature. Therefore, while comparison of the battery parameters with corresponding steady state values of the charger parameters are preferred, the battery pack 112 may still be deemed to be compatible for charging, when the peak ranges of the charger parameters are within the scope of the battery parameters. Once it is determined that the external charger 120 and the battery pack 112 are compatible for the charging process, the control circuit 108 thereon may supply the regulated power to the battery pack 112 via the second connecting portion 104. In scenarios where the regulation of the received power from the external charger 120 is not required, the control circuit 108 may supplies the received power to the battery pack 112 via the second connecting portion 104.
[0064] In a preferred embodiment, the control circuit 108 may only receive the one or more charger parameters from the external charger 120, when the first connecting portion 102 is detected to be securely coupled to the external charger 120. To this end, one or more sensors 124 may be configured in the first connecting portion 102 to detect the engagement of the output connector to the mating provisions of the first connecting portion 102. The control circuit 108, upon detection of incorrect engagement or partial engagement of the output connector of the external charger 120 with the first connecting portion 102, may transmit an input signal indicative of the same to the display unit 110.
[0065] Similarly, the control circuit 108 may receive the one or more battery parameters from the battery pack 112, when the second connecting portion 104 is detected to be securely coupled to the battery pack 112. To this end, one or more sensors 124 may be configured in the second connecting portion 104 to detect the engagement of the terminals of the battery pack 112 to the mating provisions of the second connecting portion 104. The control circuit 108, upon detection of incorrect engagement or partial engagement of the terminals with the second connectingportion 104, may transmit an input signal indicative of the same to the display unit 110. Further, the BMS coupled to the control circuit 108 may transmit the one or more battery parameters and may also indicate secure or improper coupling between the battery pack’s terminals and the second connecting portion 104.
[0066] The control circuit 108 may be further configured to transmit the one or more battery parameters to the external server 122 and the display unit 110 via the network 125 such as wired or wireless communication network. The external server 122 may be utilized as a cloud server, which retains all the battery parameters and the progressive states of the battery parameters during the charging as well as discharging operations. The external server 122 may also be used to authenticate or de-authorize the charging operation of the concerned battery pack 112 via the charger coupling device 100.
[0067] In an aspect, the external server 122 may refer to virtual or physical storage entities connecting multiple clients or users on a dedicated network. For instance, cloud servers are virtual servers, while physical servers may also be used for storing data and running applications. The “data” referred to in the present context refers to the battery and / or charger parameters. The external server 122 may alternately refer to a data management tool configured to receive and transmit the data to multiple clients or users and retain the same for future access and validation.
[0068] In an aspect, the display unit 110 may refer to a display panel or tell tales or indicators coupled to the casing 106 of the device 100. The display unit 110 may alternately be a display associated with a mobile phone, a smart phone, a personal digital assistant of the user, or a dedicated user interface providing battery operational parameters and status. The display unit 110 may be configured to provide error messages, state of charging of the battery pack 112, or other battery and external charger parameters to the user.
[0069] In an aspect, the control circuit 108 may be configured to disable communication with the battery pack 112 via the second connecting portion 104, when the one or more battery parameters exceed the corresponding threshold range of the one or more charger parameters i.e., when the battery pack 112 and the external charger 120 are not compatible with each other for the charging operation. In other words, when the battery parameters received from the BMS are determined by the control circuit 108 to be beyond the operable or threshold ranges of the external charger 120, the control circuit 108 may disconnect communication between the control circuit 108 and the BMS of the battery pack 112. The same may be indicated in the display unit 110 denoting non-compatibility. Similarly, in the event the external server 122 transmits a malware concern in view of the transmitted battery parameters, the control circuit108 may instantaneously disconnect communication between the control circuit 108 and the BMS of the battery pack 112. The same may be denoted as an error or alert on the display unit 110. For the purposes of the present disclosure, the external server 122 may be configured to perform validation or authentication of the battery pack 112 in association with the transmitted battery parameters. Therefore, any receipt of concern by the control circuit 108 may lead to instantaneous disconnect between the control circuit 108 and the BMS of the battery pack 112. The external server 122 may be similarly configured to check compatibility of the charger parameters in assessing compatibility, safety, and optimal charging of the battery pack 112. Therefore, the device 100, as per the present disclosure, ensures that the sanctity or security of the battery pack 112, the external charger 120 as well as the control circuit 108 be maintained against any unauthorized attack.
[0070] In an aspect, the control circuit 108 may be configured to disable communication with the first connecting portion 102 and the second connecting portion 104 and the supply of the regulated or received power to the battery pack 112. The disabling configuration of the device 100 by the control circuit 108 may be triggered, when one or more operating parameters, received from the one or more sensors 124 of the device 100, the external charger 120, and the battery pack 112, are beyond a respective threshold range or value. The one or more operating parameters may comprise at least a state of charge of the battery pack 112 during supply of the regulated power to the battery pack 112. For instance, the user transmits an input that only 80% State of Charge (SOC) of the battery pack 112 is to be attained. The control circuit 108 receives the SOC input in real-time from the BMS or the one or more sensors 124. Once the SOC is detected to reach 80%, the control circuit 108 may trigger an auto-cut off using one or more switching units to disable the supply of the regulated power to the battery pack 112. In a preferred embodiment, the control circuit 108 is configured to automatically disable the communication and supply of the regulated power to the battery pack 112 when 100% SOC is attained. The one or more operating parameters may further comprise a temperature of the battery pack 112, the external charger 120, and the device 100 during supply of the regulated power to the battery pack 112. In the event an over temperature is detected in any of the components, a raising concern of safety may entail. The control circuit 108 may as a precaution disable the supply of the regulated power from the external charger 120 to the battery pack 112 via the device 100. The one or more operating parameters may further comprise a user input transmitted to the control circuit 108. In the event the user input indicative of stopping of charging of the battery pack 112 is received by the control circuit 108, an auto-cut off or disabling of the power supply to the battery pack 112 may be initiated. The display unit 110may serve as an input-output interface between the device 100 and the user in receiving the user inputs and transmitting the charging status. The one or more operating parameters may further comprise a current and voltage of the battery pack 112 and the external charger 120 during supply of the regulated power to the battery pack 112. In the event, the operating parameters of the battery 112, the external charger 120, or the device 100 are indicative of over current, under current, over voltage, or under voltage scenarios, or any combination thereof, which may have grave malfunction connotations, as a safety precaution, the control circuit 108 may be configured to disable the communication and supply of the regulated power to the battery pack 112.
[0071] For a more lucid understanding of the disclosed subject matter, the one or more charger parameters and the one or more battery parameters are indicative of the battery pack 112 and external charger 120 status before initiation of the charging of the battery pack 112 by the external charger 120 via the device 100. On the other hand, the one or more operating parameters denotes the status of the device 100, the battery pack 112, and the external charger 120, when the charging or power supply to the battery pack 112 from the external charger 120 is initiated.
[0072] In an aspect, the control circuit 108 may comprise circuitry such as a processing unit 108a, a communication unit 108b, a switching unit 108c, a rectifier unit 108d, a voltage converter 108e, a fusing unit 108f, and a memory unit 108g. The control circuit 108 may be communicatively coupled to the one or more sensors 124 for procuring the one or more operating parameters. The control circuit 108 may be communicatively coupled to the external server 122 and the display unit 110 for the data transmittal and retrieval pertinent to the charging of the battery pack 112.
[0073] The processing unit 108a may include a processor and a computer-readable medium communicatively coupled to the processor. The computer-readable medium may store processor-executable instructions, which, on execution, cause the processor to determine incompatibility in the operating parameters between the external charger 120 and the battery pack 112, The processor-executable instructions, on execution, further cause the processor to adaptively transmit the battery parameters to the external server 122 and the display unit 110 for authentication, data display, and data restoration purposes. The processor-executable instructions, on execution, further cause the processor to regulate the power to be supplied to the battery pack 112 by the external charger 120 based on the compatibility assessment. The processor-executable instructions, on execution, further cause the processor to choose between offline and online modes of communication between the control circuit 108 and the externalserver 122. The processor-executable instructions, on execution, further cause the processor to receive the battery parameters, the charger parameters, and the operating parameters in ensuring optimal operation of the device 100 in supporting charging of the battery pack 112.
[0074] In yet another embodiment, a non-transitory computer-readable medium storing computer-executable instructions for the compatibility assessment between the external charger 120 and the battery' pack 112 is disclosed. In one example, the stored instructions, when executed by the processor, cause the processor to perform operations such as adaptively transmit the battery parameters to the external server 122 and the display unit 110 for authentication, data display, and data restoration purposes. The stored instructions, when executed by the processor, cause the processor to perform regulation of the received power to be supplied to the battery’ pack 112 by the external charger 120 based on the compatibility assessment, and choose between offline and online modes of communication between the control circuit 108 and the external server 122. The stored instructions, when executed by the processor, cause the processor to perform reception of the battery' parameters, the charger parameters, and the operating parameters in ensuring optimal operation of the device 100 in supporting charging of the battery pack 112.
[0075] The processing unit 108a may include at least one data processor for executing program components for executing user- or system-generated requests. The user may correspond to a person, a person using a device such as such as those included in this disclosure, or such a device itself. The processing unit 108a may include specialized processing units such as integrated system (bus) controllers, memory management control units, floating point units, graphics processing units, digital signal processing units, etc. The processing unit 108a may include a microprocessor, such as AMD® ATHLON® microprocessor, DURON® microprocessor OR OPTERON® microprocessor, ARM's application, embedded or secure processors, IBM® POWERPC®, INTEL'S CORE® processor, ITANIUM® processor, XEON® processor, CELERON® processor or other line of processors, etc. The processing unit 108a may be implemented using mainframe, distributed processor, multi-core, parallel, grid, or other architectures. Some embodiments may utilize embedded technologies like application-specific integrated circuits (ASICs), digital signal processors (DSPs), Field Programmable Gate Arrays (FPGAs), etc.
[0076] In an aspect, the communication unit 108b of the control circuit 108 is operable in one of: the online mode or the offline mode. The online mode is triggered, when a network strength associated with the communication medium between the communication unit 108b and the external server 122 is beyond a pre-set threshold. The offline mode is triggered, when thenetwork strength associated with the communication medium between the communication unit 108b and the external server 122 is below a pre-set threshold. In the offline mode the communication unit 108b is first configured to transmit the one or more battery parameters to the memory unit 108g of the control circuit 108, and then retrieve the one or more battery parameters from the memory unit 108g and transfer to the external server 122 upon the online mode being re-instated.
[0077] The processing unit 108a may be disposed in communication with one or more input / output (I / O) devices via an I / O interface, which may alternately be referred to as the communication unit 108b. The communication unit 108b may employ communication protocols / methods such as, without limitation, audio, analog, digital, monoaural, RCA, stereo, IEEE-1394, serial bus, universal serial bus (USB), infrared, PS / 2, BNC, coaxial, component, composite, digital visual interface (DVI), high-definition multimedia interface (HDMI), RF antennas, S-Video, VGA, IEEE 802.11a / b / g / n / x, Bluetooth, cellular (e.g., code-division multiple access (CDMA), high-speed packet access (HSPA+), global system for mobile communications (GSM), long-term evolution (LEE), WiMax, or the like), etc. Using the communication unit 108b, the control circuit 108 may communicate with one or more VO devices. For example, an input device (which may be via the first connecting portion 102, the second connecting portion 104, the one or more sensors 124, and / or display unit 110) may be an antenna, keyboard, mouse, joystick, (infrared) remote control, camera, card reader, fax machine, dongle, biometric reader, microphone, touch screen, touchpad, trackball, sensor (e.g., accelerometer, light sensor, GPS, gyroscope, proximity sensor, or the like), stylus, scanner, storage device, transceiver, video device / source, visors, etc. An output device such as the display unit 110 may be a printer, fax machine, video display (e.g., cathode ray tube (CRT), liquid crystal display (LCD), light-emitting diode (LED), plasma, or the like), audio speaker, etc. In some embodiments, a transceiver may be disposed in connection with the control circuit 108. Transceiver may facilitate various types of wireless transmission or reception. For example, transceiver may include an antenna operatively connected to a transceiver chip (e.g., TEXAS® INSTRUMENTS WILINK WL1283® transceiver, BROADCOM® BCM4550IUB8® transceiver, INFINEON TECHNOLOGIES® X-GOLD 918-PMB9800® transceiver, or the like), providing IEEE 802.11a / b / g / n, Bluetooth, FM, global positioning system (GPS), 2G / 3GHSDPA / HSUPA communications, etc.
[0078] In some embodiments, the processing unit 108a or the communication unit 108b may be disposed in communication with a communication network via a network interface. Network interface may communicate with communication network. Network interface may employconnection protocols including, without limitation, direct connect, Ethernet (e.g., twisted pair 50 / 500 / 5000 Base T), transmission control protocol / internet protocol (TCP / IP), token ring, IEEE 802.11a / b / g / n / x, etc. Communication network may include, without limitation, a direct interconnection, local area network (LAN), wide area network (WAN), wireless network (e.g., using Wireless Application Protocol), the Internet, etc. Using network interface and communication network, the control circuit 108 may communicate with devices. These devices may include, without limitation, personal computer(s), server(s), fax machines, printers, scanners, various mobile devices such as cellular telephones, smartphones, tablet computers, eBook readers (, laptop computers, notebooks, gaming consoles (or the like. In some embodiments, a computer system may itself embody one or more of these devices.
[0079] In an aspect, the switching unit 108c may refer to relays, electronic switches, or any other electrical component configured to route the electrical path between multiple contact points. In one configuration, for disabling the supply of the regulated power to the battery pack 112, the switching unit 108c may be operated (for example, as an open switch), which disconnects the electrical path between the external charger 120 and the battery pack 112. Similarly, when the charging of the battery pack 112 is initiated, the switching unit 108c is engaged or connected (for example, operates as a closed switch) to the contact point routing the regulated power to the battery pack 112.
[0080] In an aspect, the rectifier unit 108d refers to an electrical or electronic component configured to convert an incoming alternating current (AC) to direct current (DC). In a preferred embodiment, the battery pack 112 is charged via DC power supply. Therefore, in the event the power being supplied by the external charger 120 is AC power supply, there arises a requirement to convert the same to DC power supply for optimal charging of the battery pack 112. In such a scenario, the rectifier unit 108d converts the received AC power supply to the DC power supply and send it to the battery pack 112.
[0081] In an aspect, the control circuit 108 comprises the voltage converter 108e. The control circuit 108 regulates the power supply to the battery pack 112 via the voltage converter 108e. Upon detection of a variance between the voltage of the external charger 120 and an operating or charging voltage of the battery pack 112, the processing unit 108a may activate the voltage converter 108e. The voltage converter 108e may be configured to transform a voltage of the received power supply from the external charger 120 to a voltage level required for charging the battery pack 112. The operating voltage level of the battery pack 112 may be received from one of a memory unit 108g of the control circuit 108, and the BMS of the battery pack 112.
[0082] In an aspect, the control circuit 108 comprises the memory unit 108g. The memory unit 108g may be configured to store a pre-set list of values concerning the battery parameters in the event of intermittent lag in communication between the BMS and the communication unit 108b. In some embodiments, processing unit 108a may be disposed in communication with one or more memory units 108g (e g., RAM 926, ROM 928, etc.) via a storage interface. Storage interface may connect to memory units 108g including, without limitation, memory drives, removable disc drives, etc., employing connection protocols such as serial advanced technology attachment (SATA), integrated drive electronics (IDE), IEEE-1394, universal serial bus (USB), fiber channel, small computer systems interface (SCSI), etc. The memory drives may further include a drum, magnetic disc drive, magneto-optical drive, optical drive, redundant array of independent discs (RAID), solid-state memory devices, solid-state drives, etc.
[0083] The memory units 108g and / or the processing unit 108a may store a collection of program or database components, including, without limitation, an operating system, user interface application, web browser, mail server, mail client, user / application data (e.g., any data variables or data records discussed in this disclosure), etc. Operating system may facilitate resource management and operation of the control circuit 108. User interface or display units 110 may facilitate display, execution, interaction, manipulation, or operation of program components through textual or graphical facilities. For example, user interfaces may provide computer interaction interface elements on a display system operatively connected to control circuit 108, such as icons, check boxes, menus, scrollers, windows, widgets, etc. Graphical User Interfaces (GUIs) may be employed.
[0084] In some embodiments, the memory unit 108g may store user / application data, such as the data, variables, records, etc. as described in this disclosure. Such databases may be implemented as fault-tolerant, relational, scalable, secure databases. Alternatively, such databases may be implemented using standardized data structures, such as an array, hash, linked list, struct, structured text file, table, or as object-oriented databases. Such databases may be consolidated or distributed, sometimes among the various computer systems discussed above in this disclosure. It is to be understood that the structure and operation of the any computer or database component may be combined, consolidated, or distributed in any working combination.
[0085] In an aspect, the one or more sensors 124 coupled to the control circuit 108 may include current sensors, temperature sensors, voltage sensors, and power sensors. The one or more sensors 124 indicate optimal operation or flow of power as well as data between thedevice 100, external charger 120, and the battery pack 112. The communication may be received from the external charger 120 and transmitted to the battery pack 112 via the control circuit 108. In an embodiment, the one or more sensors 124 may include a mal firmware configured to detect bugs or anomalies in the data transmission or communication lines between the external charger 120, the control circuit 108, and the battery pack 112. The one or more sensors 124 may be also configured to detect the one or more operating parameters during the charging process of the battery pack 112, however the operating parameters shall include the parameters concerning the battery pack 112, the external charger 120 as well as the device 100.
[0086] In an aspect, the control circuit 108 comprises the fusing unit 108f. The fusing unit 108f may disconnect the regulated power supplied to the battery pack 112 in the event of an over temperature, over current, or over voltage detection in any of the device 100, the battery pack 112, and / or the external charger 120.
[0087] It will be appreciated that, for clarity purposes, the above description has been described with various embodiments of the disclosed subject matter with reference to different functional units, devices, and processors. However, it will be apparent that any suitable distribution of functionality between different functional units, devices, processors, or domains may be used without detracting from the disclosed subject matter. For example, functionality illustrated to be performed by separate processors or controllers may be performed by the same processor or controller. Hence, references to specific functional units are only to be seen as references to suitable means for providing the described functionality, rather than indicative of a strict logical or physical structure or organization.
[0088] Figure 2(a) illustrates a perspective view of the charger coupling device 100 coupled to the battery pack 112, in accordance with an embodiment of the present disclosure. Figure 2(b) illustrates a perspective view of the battery pack 112, in accordance with an embodiment of the present disclosure. For the sake of brevity, Figures 2(a) and 2(b) shall be explained in conjunction with each other. With reference to Figures 2(a) and 2(b), 112a denotes an overhang portion of the battery pack 112, 112b denotes a base of the battery pack 112, and 112c denotes terminals of the battery pack 112.
[0089] In an aspect, the device 100 in an engaged or coupled configuration with the battery pack 112 conforms to the dimensions of the battery pack 112 without any protrusion or extension observable.
[0090] In an aspect, the device 100 is accommodated, integrated, installed, mounted, placed, or positioned between the overhang portion 112a of the battery pack 112 and the base 112b ofthe battery pack 112. The overhang portion 112a adjoins a top portion of the battery pack 112 and extends beyond the vertical surfaces extending from the base 112b of the battery pack 112. The overhang portion 112a includes the terminals 112c of the battery pack 112. The terminals 112c may include one or more ports configured to align with the second connecting portion 104 of the device 100, and the one or more ports of the terminals 112c are configured to serve as a data and power communication interface between the charger coupling device 100, the external charger 120, and the battery pack 112.
[0091] In an aspect, the second connecting portion 104 of the device 100 is configured to engage or couple with the terminals 112c of the battery pack 112, when the device 100 is moved in a vertical plane from the base 112b and towards the overhang portion 112a along the vertical surfaces of the battery pack 112. When the device 100 is properly accommodated, integrated, installed, mounted, placed, or positioned between the overhang portion 112a and the base 112b of the battery pack 112, as shown in Figure 2a, the second connecting portion 104 of the device 100 engages or couples with the terminals 112c of the battery pack 112. When the second connecting portion 104 and the terminals 112c are securely coupled or engaged to each other, and when the first connecting portion 102 of the device 100 is securely coupled or engaged to the external charger 120, which may be connected to an external power source, the terminals 112c receives the power supply, which is managed by the BMS of the battery pack 112. The BMS may also regulate the received power supply, for example, the voltage and current to ensure the battery pack 112 is charged safely and efficiently. The regulated power may be delivered to the battery pack 112, where it is stored as chemical energy. The BMS also monitors the battery’s temperature and state of charge and other parameters during the charging process.
[0092] With reference to Figure 2(b), F denotes a dimension or length of the overhang portion 112a extending beyond the bottom edges or surfaces of the base 112b of the battery pack 112, which is indicated by length 1. Also, as shown, the overhang portion 112a extends beyond the vertical surfaces extending in the vertical plane from the base 112b. The base 112b of the battery pack 112 may only extend up to the length 1 and the vertical surfaces may extend perpendicular to the base 112b. The overhang portion 112a extends beyond these surfaces up to a length F, as shown, which includes the terminals 112c.
[0093] In a preferred embodiment, the width or thickness of the device 100 may be within the dimension of F, such that there is no extension or protrusion from the sides of the battery pack 112 when the device 100 is engaged with the overhang portion 112a of the battery pack 112.
[0094] With reference to Figure 2(b), the height of the battery pack 112 is denoted by h while the height of the top casing is denoted by h’. The overhang portion 112a may be an extension of the top casing and is of the same height h’ or less than h’.
[0095] In an aspect, the terminals 112c of the overhang portion 112a extend downwardly to securely engage with the second connecting portion 104 of the device 100. With reference to Figure 2(b), the thickness or width of the battery pack 112 is denoted by t.
[0096] In a preferred embodiment, the dimensions of the device 100 are equal to within the threshold values or dimensions as indicated by F, h, and t in Figure 2b, where F refers to a length of the overhang portion 112a, h refers to a height of the battery pack 112 without the overhang portion 112a, and t refers to a thickness of the battery pack 112. The disclosed configuration ensures compactness of the device 100 coupling with the battery pack 112, without any projections or protrusions accidentally interacting with the human body during battery pack charging. For instance, any projection or protruding portion of the battery and coupler combination upon impact by the human body may lead to loosening of the coupling between the terminals 112c and the second connecting portion 104 leading to unsafe charging or current flow. The present configuration minimizes the occurrences of disengagement between terminals 112c and the device 100 owing to accidental impacts on the battery pack 112 in the charging configuration. In a preferred embodiment, from a side view of the battery pack 112, the device 100 does not extend beyond or below the base 112b and beyond the overall length of the battery pack (1+F).
[0097] In an aspect, the engagement of the terminals 112c with the second connecting portion 104 may be achieved by use of one or more connecting and locking mechanisms. For example, when the second connecting portion 104 is plugged or connected into the terminals 112c, it aligns with the terminals 112c. Such design ensures that the pins make proper contact with the corresponding terminals. Some connectors may have an automatic locking mechanism that secures the connection once inserted.
[0098] In an aspect, the first connecting portion 102 is configured on an external surface of the casing 106 such that the same may be accessible at all times for external or output connector connection and disconnection. Also, the display unit 110 is configured on the external surface of the casing 106, which is accessible or viewable to the user at all times during engaged and disengaged configuration of the battery pack 112 with the device 100. For the purpose of easy access, the first connecting portion 102 and the display unit 110 may be configured on the same vertical surface of the device 100, as shown in Figure 2a.
[0099] Figure 3 illustrates an exploded view of the charger coupling device 100, in accordance with an embodiment of the present disclosure. Figure 4(a) illustrates a top view of the charger coupling device 100, in accordance with an embodiment of the present disclosure.Figure 4(b) illustrates a rear view of the charger coupling device 100, in accordance with an embodiment of the present disclosure. Figure 4(c) illustrates a side view of the charger coupling device 100, in accordance with an embodiment of the present disclosure. Figure 4(d) illustrates a front view of the charger coupling device 100, in accordance with an embodiment of the present disclosure. For the sake of brevity, Figure 3, Figures 4(a), 4(b), 4(c), and 4(d) are explained in conjunction with each other. With reference to Figure 3, Figures 4(a), 4(b), 4(c), and 4(d), 114 denotes a plurality of cover members, 116 denotes a plurality of openings, and 118 denotes a plurality of fastening units. The casing 106 comprises the control circuit 108, the first connecting portion 102, and the second connecting portion 104. Further, the first connecting portion 102 and the second connecting portion 104 may be communicatively and electrically connected to the control circuit 108.[000100] In an aspect, the casing 106 comprises the plurality of openings 116, which may enable the first connecting portion 102 and the second connecting portion 104 to protrude for access. The plurality of openings 116 may be configured such that only the mating provisions of the first connecting portion 102 and the second connecting portion 104 remain exposed, while the internal architecture is reserved or covered or enclosed by the casing 106.[000101] In an aspect, the plurality of cover members 114 may be configured to selectively cover and uncover the first connecting portion 102 and the second connecting portion 104. The cover members 114 may have a flip, sliding, or snap fit configuration to switch between positions, which cover and expose the mating provisions of the first connecting portion 102 and the second connecting portion 104.[000102] With reference to Figure 3, the casing 106 comprises one or more casing portions such as a bottom casing 106b and a top casing 106a. The top casing or top cover 106a may be secured to the bottom casing or bottom cover 106b via one or more fastening units. Alternately, the top casing 106a and the bottom casing 106b may be secured by using a snap fit configuration. In an embodiment, the interface between the top casing 106a and the bottom casing 106b may be provided with a sealing member such as a gasket or sealant. The control circuit 108, the first connecting portion 102, and the second connecting portion 104 are accommodated in the space between the top casing 106a and the bottom casing 106b. The top casing 106a and the bottom casing 106b may be provided with guide rails, guiding protrusions or rib-like structures to ensure secure disposition and mounting of the control circuit 108, thefirst connecting portion 102, and the second connecting portion 104. The guide rails, guiding protrusions, or rib-like structures ensure that any relative movement between the control circuit 108, the first connecting portion 102, and the second connecting portion 104 may be minimized. Further, the guide rails, guiding protrusions, or rib-like structures may be configured to route internal cables or wires inside the casing 106. In an embodiment, the guiding protrusions have through holes which may receive the fastening units.[000103] In an embodiment, the control circuit 108 may be provided on a printed circuit board (hereinafter referred to as PCB). The PCB may control the charging process by managing the flow of current, monitoring of the battery parameters received from the BMS and ensure safe charging of the battery pack 112. The PCB may additionally mount built-in features like analog-to-digital converters and pulse-width modulation controllers. The PCM may also include integrated circuits to manage the distribution of current and / or power within the PCB. The integrated circuits may be configured to ensure that the correct voltage and current are supplied to the associated components (such as but not limited to the battery pack 112), thereby protecting the associated components from power surges and efficient charging operation. The control circuit 108 is connected to the first connecting portion 102 via a wiring harness. The wiring harness may be routed in the space between the top casing 106a and the bottom casing 106b via one or more guiding structures. The second connecting portion 104 is connected to the control circuit 108 via a wiring harness, which may be routed in the space between the top casing 106a and the bottom casing 106b via one or more guiding structures.[000104] In an aspect, the control circuit 108 being securely held in the space between the top casing 106a and the bottom casing 106b provides a waterproof configuration. A sealant or gasket between the top casing 106a and the bottom casing 106b further improves the waterproof nature of the charger coupling device 100. Further, the charger coupling device 100 comprising components such as the control circuit 108, the first connecting portion 102, and the second connecting portion 104 at least partially enclosed by the casing 106 via plurality of fastening units ensures accessibility to the individual components in the event of error detection. The ease of disassembly and assembly of the charger coupling device 100 is achieved by providing the casing in two parts and coupled via fastening units or snap fit.[000105] In an aspect, the display unit 110 may be provided on the top casing 106a of the charger coupling device 100. The display unit 110 may comprise light emitting diodes, tell tales, a digital cluster, analog cluster, or other forms of displays. The display unit 110, being communicatively coupled to the control circuit 108, provides an active operating status of the charger coupling device 100 in real-time. The active operating status may indicate deviceerrors, battery charging, incompatibility between external charger and battery pack, battery pack SOC.[000106] In a preferred embodiment, the first connecting portion 102 may be mounted on installed on a front surface (of the top casing 106a) of the charger coupling device 100 while the second connecting portion 104 may be mounted or installed on a top surface of the charger coupling device 100.[000107] In an aspect, the casing 106 may include an additional locking mechanism via which the access to the internal components of the charger coupling device 100 may be granted. The locking mechanism may be used to authenticate access to the charger coupling device’s 100 internal components such as the control circuit 108, the first connecting portion 102, and the second connecting portion 104.[000108] With reference to Figure 4(a), the second connecting portion 104 has been shown mounted through its opening 116. Further, the fastening units 118 may be used to mount or install the second connecting portion 104 through its opening 116 on a top portion of the top casing 106a. The fastening units 118 may be provided alongside or around the second connecting portion 104. The fastening units 118 may be synchronously operative with one or more springs. The combination of the fastening units 118 with the springs help retain the position and coupling of the charger coupling device 100 relative to the terminals 112c of the battery pack 112. Further, the springs help prevent a direct impact owing to movement of the second connecting portion 104 against the terminals 112c of the battery pack 112 (referring Figure 2(a)) for electrical and communication engagement between the terminals of the battery pack 112 with the mating provision of the second connecting portion 104. The direct impact may have damaged either the terminals 112c of the battery pack 112 or the mating provisions of the second connecting portion 104.[000109] Figure 4(b) shows a rear view of the charger coupling device 100 and illustrates the cover member 114, which may be used to cover or uncover the second connecting portion 104 to protect the mating provisions of the second connecting portion 104 against accidental damage, as well as mud, water or dirt ingress. Further, as shown, a width of the charger coupling device 100 (enclosed within the casing 106) at a top portion (around the second connecting portion 104) is more than a width of the charger coupling device 100 (enclosed within the casing 106) at a bottom portion.[000110] Figure 4(c) illustrates a side view of the charger coupling device 100 with the first connecting portion 102 mounted or installed on a front surface of the device 100. In some embodiments, the device 100 may be provided with heat dissipating structures such as fins orcoolant guideways provided along the external or internal surfaces of the casing 106. In an embodiment, the heat dissipating structures are provided on the external surface of the casing 106 adjoining or linked with the casing surface which receives and secures the control circuit 108. Owing to the high processing requirements of the control circuit 108, the control circuit 108 is more susceptible to higher heat radiations or emanation, therefore requiring an adjoining or associated heat dissipation mechanism.[000111] Figure 4(d) illustrates a front view of the charger coupling device 100 coupled to the battery pack 112. As depicted, a portion of the battery pack 112 is completely eclipsed or covered by the device 100. The first connecting portion 102, which has been mounted through its opening 116, is exposed or accessible to the user for connecting an external connector of the external charger 120. The display unit 110 may be disposed on the same surface as the first connecting portion 102, which ensures that the user has continuous access to the active operating status of the charger coupling device 100.[000112] Figures illustrates an exemplary flowchart 500 of a method for charging the battery pack 112 by using the charger coupling device 100. The flowchart 500 starts at step 502 and proceeds to step 504.[000113] At step 504, the one or more charger parameters are received. In an embodiment, the control circuit 108 may be configured to receive the one or more charger parameters from the external charger 120, when the device 100 is securely coupled to the external charger 120 via the first connecting portion 102. An output connector of the external charger 120 may be coupled to the mating provisions of the first connecting portion 102, thereby enabling the communication between them. The one or more charger parameters may include at least a current rating, a voltage rating, a power rating, and a temperature rating of the external charger 120, but should not be construed as limiting to the scope of the disclosed subject matter. The current rating, voltage rating, power rating, and temperature rating are indicative of an optimal operational range of the external charger 120 during the charging or discharging process. The flow chart 500 then proceeds to step 506.[000114] At step 506, the one or more battery parameters are received. In an embodiment, the control circuit 108 may be configured to receive the one or more battery parameters from the battery pack 112, when the device 100 is securely coupled to the terminals 112c of the battery pack 112 via the second connecting portion 104. The one or more battery parameters may include at least: a current rating, a voltage rating, a temperature rating, a power rating, a state of charge, and a state of health of the battery pack 112. Each of the current rating, voltage rating, power rating, temperature rating, state of charge rating, and state of health rating isindicative of an optimal operational range or value of the battery pack 112 during the charging process. The flow chart 500 then proceeds to step 508.[000115] At step 508, a check is performed to determine whether the one or more battery parameters are within the corresponding threshold range or value of the one or more charger parameters. In an embodiment, the control circuit 108 may be configured to perform the check by comparing the one or more battery parameters with the corresponding threshold range or value of the one or more charger parameters. By performing this check, the control circuit 108 adjudges the compatibility of the external charger 120 for charging the battery pack 112. When it is determined that the one or more battery parameters are within the corresponding threshold range or value of the one or more charger parameters, the flowchart 500 proceeds to step 510, else the flowchart 500 proceeds to step 514.[000116] At step 510, the power, received from the external charger 120 and to be supplied to the battery pack 112, is regulated. In an embodiment, the control circuit 108 may be configured to regulate the received power to be supplied to the battery pack 112 for optimized charging of the battery pack 112. The control circuit 108 thereof regulates the received power, which is to be supplied to the battery pack 112, when the one or more battery parameters are within the corresponding threshold range of the one or more charger parameters. The flowchart 500 then proceeds to step 512. However, in scenarios where the received power is already regulated one, then this step 510 may be skipped and the flowchart 500 then proceeds to step 512 from step 508.[000117] At step 512, the regulated power is supplied to the battery pack 112 via the second connecting portion 104, which is coupled to the terminals 112c of the battery pack 112. The flowchart 500 then proceeds to step 518 and the process ends.[000118] At step 514, the communication with the battery pack is disabled. In an embodiment, the control circuit 108 may be configured to disable or disconnect the communication established between the device 100 and the battery pack 112 when the compatibility of the external charger 120 for charging the battery pack 112 fails. The control circuit 108 may be configured to disable the communication with the battery pack 112 via the second connecting portion 104, when the one or more battery parameters exceed the corresponding threshold range or value of the one or more charger parameters. In other words, when the battery parameters received from the BMS are determined by the control circuit 108 to be beyond the operable or threshold ranges of the external charger 120, the control circuit may disconnect communication between the control circuit 108 and the BMS of the battery pack 112. The flowchart 500 then proceeds to step 516.[000119] At step 516, an error message is displayed. In an embodiment, the control circuit 108 may be configured to transmit the error message to the display unit 110 and the external server 122. The error message may be indicative of non-compatibility between the battery pack 112 and the external charger 120. Alternately, in the event the external server 122 transmits a malware concern in view of the transmitted battery parameters, the control circuit 108 may instantaneously disconnect communication between the control circuit 108 and the BMS of the battery pack 112. The same may be denoted as an error or alert on the display unit. For the purposes of the present disclosure, the external server 122 may be configured to perform validation of authentication of the battery pack 112 in association with the transmitted battery parameters. Therefore, any receipt of concern by the control circuit 108 may lead to instantaneous disconnect between the control circuit 108 and the BMS of the battery pack 112. The external server 122 may be similarly configured to check compatibility of the charger parameters in assessing compatibility, safety and optimal charging of the battery pack 112. The flowchart 500 ends at step 518.[000120] The present disclosure is related to the charger coupling device 100. The charger coupling device 100 comprises at least the first connecting portion 102, the second connecting portion 104, and the control circuit 108. The control circuit 108 receives the one or more charger parameters from the external charger 120 via the first connecting portion 102 and the one or more battery parameters from the battery pack 112 via the second connecting portion 104. The control circuit 108 determines the regulated power to be supplied to the battery pack 112, when the one or more battery parameters are within a corresponding threshold range of the one or more charger parameter. The regulated power is supplied to the battery pack 112 via the second connecting portion 104. The control circuit 108 may disable any communication between the second connecting portion 104 and the battery pack 112, when the one or more battery parameters are beyond a corresponding threshold range of the one or more charger parameter.[000121] The claimed invention includes technical details such as regulating power to be supplied to the battery pack 112 based on the charger parameters and battery parameters. The control circuit 108 may additionally disable charging of the battery pack 112, when device parameters are indicative of a safety hazard. The device parameters are indicative of changes in battery parameters during the battery charging process, therefore permitting real time monitoring of battery parameters during charging. These technical details suggest a practical and tangible implementation. The claimed invention integrates various components, including the control circuit 108, the one or more sensors 124, the first connecting portion 102 and thesecond connecting portion 104. The coordination of these components for the specific purpose of charging a battery pack 112 adds a level of complexity beyond abstract concepts.[000122] The invention is non-obvious to a person skilled in the art, and the specific conditions, such as receiving charger parameters and battery parameters for determining an optimal or regulated power supply to the battery pack 112 for charging, contribute to the nonobviousness of the claimed invention. In view of the above, the claimed invention may not be considered abstract and may not be obvious to a person skilled in the art.[000123] The charger coupling device 100 as per the present configuration is a light-weight compact device, comprising a control circuit. The overall compact layout of the charger coupling device 100 (as depicted in Figure 2(a)) permits easy carriage or portability of the charger coupling device 100 in a bag, hand or even in a pocket. The disclosed configuration permits the vehicle user to charger their respective battery pack 112 without worrying about charger compatibility. The internal components of the charger coupling device 100 such as, but not limited to, the rectifier 108d, the voltage converter 108e, the communication unit 108b, the processing unit 108a, switching unit 108c and the fusing unit 108f provide efficient and safe charging of the battery pack 112 to which the charger coupling device 100 is engaged to. The internal components may further include a wiring harness and additional cooling mechanisms. The casing 106 of the charger coupling device 100, in an embodiment, includes an LED display screen which indicates the charging status and charging percentage of the battery pack 112 to which the charger coupling device 100 is engaged with, as well as other error messages concerning the external charger 120, the battery pack 112 as well as the charger coupling device 100 during and before a charging session be triggered or requested. In some embodiments, the control circuit 108 may alternately be referred to as an intelligence telematics control unit. The casing 106 additionally accommodates the first connecting portion 102 serving as an interface between the control circuit 108 and the external charger 120; and the second connecting portion 104 serving as an interface between the control circuit 108 and the battery pack 112. Further, to protect the mating provisions of the first connecting portion 102 and the second connecting portion 104, one or more cover members 114 eclipse or cover the respective mating provisions during a non-charging session. The one or more cover members 114 covering the mating provisions of the first connecting portion 102 and the second connecting portion 104 ensure no accidental ingress of dust, water, mud, moisture or external impact is transmitted onto the respective mating provisions.[000124] In an exemplary operating example, a user may plug in an external connector or power connector of an external charger 120 into the first connecting portion 102 of the chargercoupling device 100. The external charger may be a 650W off board charger which supplies DC power to the charger coupling device 100. The control circuit 108 of the charger coupling device 100 may detect the incoming DC current from the external charger 120 using one or more sensors 124 as well as the one or more charger parameters transmitted to the control circuit 108 via the data transmission lines of the external connector. The user may further engage or mate the second connecting portion 104 of the charger coupling device 100 with the terminals 112c of the battery pack 112. The secure connection between the mating provisions of the second connecting portion 104 and the terminals 112c of the battery pack 112, establish an electric as well as data communication, via which the BMS of the battery pack 112 transmits the one or more battery parameters to the control circuit 108. The control circuit 108 (which may be an intelligent telematics control unit (alternately referred to as iTCU)) may check whether the battery parameters or specifications map with the charger specifications or parameters. Once the battery parameters such as voltage, temperature, and power rating are within the specification range of the charger, the iTCU may initiate charging of the battery pack 112 by routing the DC current from the external charger 120 to the battery pack 112. The routing of the DC current may be achieved by enabling a switching unit 108c once the voltage converter 108e of the control circuit 108 steps down the voltage from the external charger 120 to the battery voltage limits. Further, the iTCU may be configured to determine a charging rate of the battery pack 112 based on time available for charging provided as user input, and the charging current specifications of the battery pack 112. During battery pack charging, communication between the iTCU and the BMS is retained for monitoring a charging level, charging rate or State of Charge of the battery pack 112. Once, the control circuit 108 receives an input from the BMS or from the one or more sensors 124 that 100% SOC of the battery pack 112 is attained, the control circuit 108 automatically disables the power and data communication between the charger coupling device 100 and the battery pack 112. Alternately, the user may disengage the charger coupling device 100 from the terminals 112c of the battery pack 112 to disable charging fo the battery pack 112. The disabling of power and data communication may be attained by operating the switching unit 108c. This concrete application may make it less likely to be considered abstract.[000125] In light of the above-mentioned advantages and the technical advancements provided by the disclosed system and method, the claimed system and the undertaken method of operation as discussed above are not routine, conventional, or well understood in the art, as the claimed system and claimed method enable the following solutions to the existing problemsin conventional technologies. Further, the claimed system and constructional features provide a technical solution to a technical problem.[000126] Finally, the language used in the specification has been principally selected for readability and instructional purposes, and it may not have been selected to delineate or circumscribe the inventive subject matter and is therefore intended that the scope of the invention be limited not by this detailed description, but rather by any claims that issue on an application based here on. Accordingly, the embodiments of the present invention are intended to be illustrative, but not limiting, of the scope of the invention, which is set forth in the following claims.[000127] While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. A person with ordinary skills in the art will appreciate that the systems, modules, and sub-modules have been illustrated and explained to serve as examples and should not be considered limiting in any manner. It will be further appreciated that the variants of the above disclosed system elements, modules, and other features and functions, or alternatives thereof, may be combined to create other different systems or applications. Those skilled in the art will appreciate that any of the aforementioned system modules or steps in the method may be suitably replaced, reordered, or removed, and additional steps and / or system modules may be inserted, depending on the needs of a particular application. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from its scope. Therefore, it is intended that the present disclosure not be limited to the particular embodiment disclosed, but that the present disclosure will include all embodiments falling within the scope of the appended claims.[000128] Furthermore, one or more computer-readable storage media may be utilized in implementing embodiments consistent with the present disclosure. A computer-readable storage medium refers to any type of physical memory' on which information or data readable by a processor may be stored. Thus, a computer-readable storage medium may store instructions for execution by one or more processors, including instructions for causing the processor / s) to perform steps or stages consistent with the embodiments described herein. The term ‘■‘computer-readable medium’'' should be understood to include tangible items and exclude carrier waves and transient signals, i.e., be non-transitory. Examples include random access memory (RAM), read-only memory (ROM), volatile memory, non-volatile memory, hard drives, CD ROMs, DVDs, flash drives, disks, and any other known physical storage media.[000129] A description of an embodiment with several components in communication with each other does not imply that all such components are required. On the contrary, a variety of optional components are described to illustrate the wide variety of possible embodiments of the invention.[000130] Finally, the language used in the specification has been principally selected for readability and instructional purposes, and it may not have been selected to delineate or circumscribe the inventive subject matter. It is therefore intended that the scope of the invention be limited not by this detailed description, but rather by any claims that issue on an application based here on. Accordingly, the embodiments of the present invention are intended to be illustrative, but not limiting, of the scope of the invention, which is set forth in the following claims.[000131] While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.[000132] The present disclosure may be realized in hardware, or a combination of hardware and software. The present disclosure may be realized in a centralized fashion, in at least one computer system, or in a distributed fashion, where different elements may be spread across several interconnected computer systems. A computer system or other apparatus adapted for carrying out the methods described herein may be suited. A combination of hardware and software may be a general -purpose computer system with a computer program that, when loaded and executed, may control the computer system such that it carries out the methods described herein. The present disclosure may be realized in hardware that comprises a portion of an integrated circuit that also performs other functions.Table of Reference Numerals:100 Charger coupling device102 First Connecting portion104 Second connecting portion106 Casing106a Upper casing106b Lower casing108 Control CircuitDisplay unitBattery Packa Overhang portionb Base of battery packc Terminals of battery pack One or more cover members Plurality of openings Plurality of fastening units External Charger a Processing Unitb Communication unitc Switching Unitd Rectifier unite Voltage Converterf Fusing UnitExternal ServerOne or more sensors
Claims
We Claim:
1. A charger coupling device (100) configured to couple an external charger (120) to a battery pack (112), the charger coupling device (100) comprising:a first connecting portion (102) being configured to detachably couple to an output connector of an external charger (120);a second connecting portion (104) being configured to detachably couple to terminals (112c) of a battery pack (112);a casing (106); anda control circuit (108), the control circuit (108) enclosed in the casing (106) and configured to:receive one or more charger parameters from the external charger (120), when the charger coupling device (100) is coupled to the external charger (120);receive one or more battery parameters from the battery pack (112), when the charger coupling device (100) is coupled to the battery pack (112);regulate power, received from the external charger (120), to be supplied to the battery pack (112), when the one or more battery parameters are within a corresponding threshold range of the one or more charger parameters; and supply the regulated power to the battery pack (112) via the second connecting portion (104).
2. The charger coupling device (100) as claimed in claim 1, wherein the one or more battery parameters include at least one of: a current rating, a voltage rating, a temperature rating, a power rating, a state of charge, and a state of health of the battery pack (112), and wherein the one or more charger parameters include at least one of: a current rating, a voltage rating, a power rating, and a temperature rating of the external charger (120).
3. The charger coupling device (100) as claimed in claim 1, wherein the casing (106) comprises:a plurality of openings (116), the plurality of openings (116) being configured to receive at least the first connecting portion (102) and the second connecting portion (104), anda plurality of cover members (114), the plurality of cover members (114) being configured to selectively cover and uncover the first connecting portion (102) and the second connecting portion (104).
4. The charger coupling device (100) as claimed in claim 1, wherein the control circuit (108) is configured to:receive the one or more charger parameters from the external charger (120) when the first connecting portion (102) being detected to be securely coupled to the external charger (120);receive the one or more battery parameters from the battery pack (112) when the second connecting portion (104) being detected to be securely coupled to the battery pack (112); andtransmit the one or more battery parameters to an external server (122) and a display unit (110) via a communication network (125).
5. The charger coupling device (100) as claimed in claim 1, wherein the control circuit (108) is configured to disable communication with the battery pack (112) via the second connecting portion (104), when the one or more battery parameters exceed the corresponding threshold range of the one or more charger parameters.
6. The charger coupling device (100) as claimed in claim 1, wherein the control circuit (108) is configured to:disable communication with the first connecting portion (102) and the second connecting portion (104); anddisable the supply of regulated power to the battery pack (112), when one or more operating parameters received from the charger coupling device (100), the external charger (120), and the battery pack (112) are beyond a threshold range,the one or more operating parameters comprise at least one of:a state of charge of the battery pack (112) during supply of regulated power to the battery pack (112),a temperature of the battery pack (112) and the device (100) during supply of regulated power to the battery pack (112),a user input transmitted to the control circuit (108), anda current and voltage of the battery pack (112) and external charger (120) during supply of regulated power to the battery pack (112).
7. The charger coupling device (100) as claimed in claim 1, wherein the regulation of the power supply comprises at least:activation of a voltage converter (108e), by a processing unit (108a) of the control circuit (108),the voltage converter (108e) being configured to transform a voltage of the received power supply from the external charger (120) to a voltage level required for charging the battery pack (112), the voltage level being received from one of:a memory unit (108g) of the control circuit (108), or a battery management system (BMS) of the battery pack (112).
8. The charger coupling device (100) as claimed in claim 1, comprising a communication unit (108b) of the control circuit (108) being operable in one of:an online mode, when a network strength associated with a communication medium (between the communication unit (108b) and the external server (122) being beyond a pre-set threshold, oran offline mode, when the network strength associated with the communication medium between the communication unit (108b) and the external server (122) being below a pre-set threshold,wherein the communication unit (108b) being configured to:transmit the one or more battery parameters to a memory unit (108g) of the control circuit (108), when the communication unit (108b) being operable in offline mode, andretrieve the one or more battery parameters from the memory unit (108g) and transfer to the external server (122) upon the online mode being re-instated.
9. The charger coupling device (100) as claimed in claim 1, wherein the charger coupling device (100) being accommodated or installed between an overhang portion (112a) of the battery pack (112) and a base (112b) of the battery pack (112),the overhang portion (112a) comprising terminals (112c) of the battery pack (112); andthe second connecting portion (104) of the charger coupling device (100) being configured to securely coupled to the terminals (112c) of the battery pack (112).
10. A control circuit (108) for a charger coupling device (100), the control circuit (108) comprising:a communication unit (108b) configured to:receive one or more charger parameters from an external charger (120), when the charger coupling device (100) being securely coupled to the external charger (120);receive one or more battery parameters from a battery pack (112), when the charger coupling device (100) being securely coupled to terminals of the battery pack (112); andtransmit at least the one or more battery parameters to an external server (122) and a display unit (110);a processing unit (108a) configured to:receive the one or more battery parameters and the one or more charger parameters from the communication unit (108b);regulate power, from the external charger (120), to be supplied to the battery pack (112), when the one or more battery parameters are within a corresponding threshold range of the one or more charger parameters; and a switching unit (108c) operatively coupled to the processing unit (108a) and configured to enable supply of the regulated power to the battery pack (112).
11. The control circuit (108) as claimed in claim 11, wherein the communication unit (108b) being operable in one of:an online mode, when a network strength associated with a communication medium between the communication unit (108b) and the external server (122) being beyond a pre-set threshold, oran offline mode, when the network strength associated with the communication medium between the communication unit (108b) and the external server (122) being below the pre-set threshold,wherein the communication unit (108b) being configured to:transmit the one or more battery parameters to a memory unit (108g) of the control circuit (108), when the communication unit (108b) being operable in the offline mode, andretrieve the one or more battery parameters from the memory unit (108g) and transfer to the external server (122) upon the online mode being re-instated.
12. The control circuit (108) as claimed in claim 11, wherein the regulation of the power supply comprises:activation of a voltage converter (108e), by the processing unit (108a), the voltage converter (108e) being configured to transform a voltage of the received power supply from the external charger (120) to a voltage level required for charging the battery pack (112), the voltage level being received from one of:a memory unit (108g) of the control circuit (108), or a battery management system (BMS) of the battery pack (112).
13. The control circuit (108) as claimed in claim 11, wherein the control circuit (108) being configured to disable communication with the battery pack (112) via the second connecting portion (104), when the one or more battery parameters exceed the corresponding threshold range of the one or more charger parameters.
14. The control circuit (108) as claimed in claim 11, the control circuit (108) being configured to:disable the supply of the regulated power to the battery pack (112), when one or more operating parameters, received from the charger coupling device (100), the external charger (120), and the battery pack (112), are beyond a threshold range, the one or more operating parameters comprise at least one of:a state of charge of the battery pack (112) during supply of regulated power to the battery pack (112),a temperature of the battery pack (112) and the charger coupling device (100) during supply of the regulated power to the battery pack (H2),a user input transmitted to the control circuit (108), anda current and voltage of the battery pack (112) and the external charger (120) during supply of the regulated power to the battery pack (112).