Articulated Arm Current Collector for Overhead EV Charging
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Solution Overview
Problem
Existing power transmission devices for electric vehicles, particularly in local public transport, are not optimized for compactness, weight, and reliability in stationary charging, often requiring significant infrastructure and being inflexible for overhead charging systems, with a lack of efficient contact solutions for phase and ground connections.
Innovation Solution
A compact and lightweight power transmission device featuring an articulated arm system with multiple insulated contact elements, including a grounding contact, allowing for quick and safe electrical contacting of overhead charging stations, with a single base frame and pivotable articulated arm for efficient positioning and reduced risk of short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional pantograph systems are used for stationary charging, then electrical contact can be established, but the device becomes heavy and complex
Solution Approach 1:
The current collector is divided into multiple independent articulated arms, each capable of independent movement and contact establishment. This segmentation allows each arm to be lighter while maintaining overall system reliability through redundancy and independent operation.
Solution Approach 2:
The system transitions from rigid fixed-contact pantographs to dynamic articulated arms that can automatically adjust their position and angle. This dynamic capability allows the contact elements to maintain reliable electrical contact while reducing the structural weight through optimized, movable components.
2Reliability
If multiple separate current collectors are used for different phases, then electrical contact reliability is improved, but device complexity increases
Solution Approach 1:
Multiple contact elements for different electrical phases are integrated into a single articulated arm system. The arm carries multiple contact elements that can simultaneously contact different phases, merging what would otherwise be separate current collectors into one unified structure, thereby reducing overall system complexity while maintaining phase contact reliability.
Solution Approach 2:
The articulated arm system is designed to perform multiple functions: it can contact different electrical phases, provide grounding connections, and adapt to various charging station configurations. This multi-functionality eliminates the need for separate dedicated collectors for each function, reducing device complexity while ensuring reliable contact for all electrical requirements.
3Adaptability or versatility
If articulated arm systems are used for overhead charging, then infrastructure needs are reduced, but mechanical load resistance becomes challenging
Solution Approach 1:
The articulated arms incorporate joints and actuators that provide dynamic adjustment capability, allowing the system to adapt to different charging station positions and vehicle orientations. This dynamic design enables the arms to distribute mechanical loads optimally across their structure and connection points, enhancing load resistance while maintaining adaptability to various infrastructure configurations.
Solution Approach 2:
The articulated arm structure utilizes composite materials that combine high strength-to-weight ratio properties. These composite materials provide the necessary mechanical strength to withstand high loads during charging operations while keeping the overall weight low, thereby enabling infrastructure reduction without compromising mechanical load resistance.
4Volume of moving object
If contact elements are arranged closely to reduce space, then compactness is improved, but short circuit risk increases
Solution Approach 1:
The contact elements are arranged in a compact configuration on the articulated arm, but the arm's dynamic positioning capability ensures that during operation, the contact elements maintain optimal spacing and alignment with their respective contact points. This dynamic adjustment prevents accidental contact between different phase elements, reducing short circuit risk while preserving compact overall dimensions.
Solution Approach 2:
The articulated arm structure itself serves as an intermediary that physically separates and insulates the contact elements from each other while maintaining their compact arrangement. The arm's structure and insulation materials act as mediators that prevent electrical breakdown between closely spaced contact elements, enabling compact design without increasing short circuit risk.
Data Source
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AI summary
The invention relates to a vehicle-side current transmission device (4) for the stationary charging of electrical energy stores of vehicles (7) at charging stations by means of current-supplying contact surfaces (13, 14, 15) arranged above the vehicle (7), wherein a charge current collector (4) formed as an articulated arm system (4) is designed to be multi-pole and has, for making stationary contact with the contact surfaces (13, 14, 15) to be supplied with current, at least two electrical contact elements (1, 2, 3) isolated from one another, which transmit different electrical phases. On the basis of the present invention, the charge current collector is used to create a current transmission device, which enables at least two or a plurality of electrical contacts to be made via one single current collector, said electrical contacts being able to transmit different electrical phases while earthing the vehicle at the same time. The design as an articulated arm system allows the current transmission device according to the invention to be implemented in an especially compact design with low weight. A vehicle-side charging device thus designed enables the vehicle driver to simply position the vehicle below the overhead charging station, coupled with a reliable contacting of the contact surfaces.