Ground-Mounted EV Charging Contact Device with Segmented Moveable Units
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Solution Overview
Problem
Existing fast charging systems for electric vehicles require large contact units and complex positioning devices, necessitating structural modifications to the ground, which is costly and labor-intensive, and are not easily adaptable to different vehicle types or positions.
Innovation Solution
A contact device with a base frame attachable to the ground, featuring a dielectric contact unit carrier with moveable contact elements and a modular design, allowing flexible placement and adaptation to various vehicle types, eliminating the need for ground excavation and enabling high-current transmission without additional structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If fast charging systems use large contact units to transmit high currents (500 A to 1,000 A at 750 V), then the current transmission capability is improved, but the contact unit dimensions and device complexity increase
Solution Approach 1:
The contact device is divided into multiple contact units, each handling a portion of the total current. This segmentation allows the system to transmit high currents (500 A to 1,000 A) while each individual contact unit maintains manageable dimensions, making the overall system more adaptable and easier to integrate without requiring excessive space or structural modifications.
Solution Approach 2:
The contact device is designed with universal applicability across different vehicle types (cars, trucks, busses) and can be positioned in various locations (ground level, vehicle roof, vehicle floor). This multi-functionality allows the same contact unit design to serve multiple purposes and configurations, reducing the need for specialized large-scale contact units for each application.
2Measurement precision
If a positioning device is disposed below the vehicle requiring ground excavation, then the positioning accuracy is improved, but the installation effort and cost increase
Solution Approach 1:
Instead of placing the positioning device below the vehicle requiring ground excavation, the invention inverts the approach by positioning the contact device at ground level or on the vehicle. This eliminates the need for costly ground structural measures while maintaining positioning accuracy through alternative positioning mechanisms that do not require subsurface installation.
Solution Approach 2:
The positioning function is extracted from the ground-based infrastructure and integrated directly into the contact device or vehicle system. This allows positioning to be achieved without modifying the ground structure, thereby reducing installation effort and cost while maintaining the necessary positioning accuracy for proper contact alignment.
3Ease of manufacture
If the contact device is disposed at ground level without structural modifications, then the ease of installation is improved, but the positioning precision may worsen
Solution Approach 1:
The contact units are designed with moveable components that can dynamically adjust their position during the charging process. This dynamic capability allows the system to compensate for positioning variations and maintain precise electrical contact even when the device is installed at ground level without structural modifications, thereby preserving positioning precision while ensuring easy installation.
Data Source
AI summary
A contact device for a fast charging system for electrically driven vehicles includes a charging contact device disposable on a vehicle floor, the contact device having a contact unit carrier with contact units electrically connectable to a respective charging contact of the charging contact device to form a contact pair, the contact device or the charging contact device including a positioning device, the contact units positionable relative to the charging contacts by the positioning device to form an electrically conductive connection between the vehicle and a stationary charging station, the contact device being disposable on a ground below the vehicle, the contact device having a base frame attachable to the ground, the contact unit carrier being inserted into the base frame, the contact unit carrier being made of a dielectric material, the contact units each having a contact element moveable relative to the contact unit carrier.